Is it better to have more positions in the stator and rotor windings?

On automated motor production lines, the winding process serves as the critical link between the “iron core” and the “finished product.” Whether for new energy vehicle drive motors, home appliance motors, or industrial servo motors, the quality and efficiency of winding directly determine the motor's performance stability and the overall production line capacity.

As smart manufacturing advances, more motor manufacturers face a seemingly “rational” yet thought-provoking question when selecting winding equipment: “To boost output, does a higher number of winding stations automatically mean better?”

This question involves multiple factors—equipment investment, production cycle time, maintenance costs, and changeover flexibility. Today, we delve into the truth behind the “number of stations.”

What is a winding station?

In automated stator and rotor winding machines, a “station” refers to an independent functional unit completing a specific process step in the winding sequence. A complete winding process typically includes: loading/clamping, threading/lead-in, spindle winding, wire cutting/crimping, shaping, and unloading/inspection.

Based on product structure, winding machines can be categorized as single-station, multi-station, or fully integrated automated systems.

Does a higher number of stations automatically mean greater production capacity?

Theoretically, adding stations does enhance production efficiency. Here are the three core advantages of multi-station winding machines:

(1) Reduced cycle time, boosting throughput per unit (TPS)

(2) Support for complex winding processes

(3) Easier integration into automated production lines

However, excessive workstations may backfire, leading to: exponentially higher equipment costs (each station requires independent spindle motors, tension control systems, fixtures/positioning mechanisms, sensors, and pneumatic components); larger footprints with layout constraints; increased maintenance complexity; higher failure rates; prolonged changeover times; reduced flexibility; and extended return-on-investment cycles.

Drawing from years of experience serving new energy vehicles, rail transit, and automotive electric components, we've developed a “match-to-need” selection logic to help clients avoid the pitfalls of “over-engineering” or “under-capacity.”

Define production targets → Assess product complexity → Consider changeover frequency → Reserve expansion space

In automated assembly of motor stators and rotors, the number of winding machine stations is never an isolated technical parameter. It requires coordinated consideration across multiple dimensions: product characteristics, production capacity requirements, changeover frequency, factory space, and investment budget.

【25 Years of Dedication in Motor Equipment】

Building on Quality, Founded on Integrity—Specializing in R&D of Customized Automated Motor Equipment Solutions! Specializing in the R&D and manufacturing of a full range of customized automated equipment, including stator/rotor winding machines, internal winding machines, automatic core punching machines, magnetic tile machines, carbon brush machines, and fan blade machines. Every piece of equipment adheres to the production standard of “Precision First, Durable and Reliable,” providing intelligent automated production solutions for motor manufacturers.

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