How to wind high quality coils by motor winding machine?

The quality of motor winding is one of the key factors determining the overall quality of the motor: the better the quality of the winding, the better the performance and durability of the motor is naturally guaranteed. However, in actual production, affected by a variety of factors, the winding effect is often unsatisfactory. So what are the main reasons for poor winding quality? How to wind high-quality coils? And what core details need to pay attention to? The following is a detailed analysis:

First, the core reasons affecting the quality of winding

Difference in the performance of the winding machine

from the basis of the equipment, high-quality winding machine in terms of precision control, stability and other aspects far more than the poor quality equipment, can fundamentally protect the uniformity and consistency of the winding, reduce the quality of mechanical errors caused by the problem.

Improper debugging of the parameters of the winding machine

The reasonable setting of the winding parameters directly affects the effect, need to focus on two points:

Speed control: the winding speed should not be too fast, the start-up needs to be “slow winding” mode, to avoid inertia caused by the wire arrangement disorder;

Tension adjustment: according to the characteristics of the wire in the equipment within the control range of precision tension adjustment, to ensure that the tension is stable and “leave room for error” - tension is too large easy to cause wire breakage, insulation layer damage, too small may lead to loose coil.

Differences in the characteristics of the wire itself

Parameters such as the material, hardness and wire diameter of the wire will directly affect the winding effect:

Even if the material is the same, if there are deviations in hardness or wire diameter, the tightness and flatness of the wound wire will be significantly different;

When selecting enameled wire, it is recommended to give priority to the selection of softer wire (e.g., aluminum wire is lower than copper wire due to its hardness, and the winding effect is better in some scenarios), which can reduce the “anti-deformation” resistance in the process of winding, and improve the coil's regularity.

Key Principles of High Quality Coil Winding

In order to wind high quality coils, it is necessary to combine equipment performance, parameter adjustment and wire characteristics: fully understand the performance limits of the winding machine, accurately set the speed and tension parameters, and at the same time, optimize the operational details according to the characteristics of the wire (e.g., hardness, wire diameter). Only by comprehensively controlling these elements can we ensure a stable and efficient winding process, and ultimately obtain high-quality coils that are neatly aligned, uniformly tensioned, and well insulated, laying the foundation for the reliable operation of motors.