In ensuring that the configuration of the motor stator winding machine meets production requirements, a systematic inspection must be conducted from multiple dimensions, including equipment performance, core components, winding accuracy, and other details. The following will detail the specific inspection points and operational standards, providing a reference basis for equipment commissioning and daily maintenance.
1. Verification of Basic Equipment Performance
The basic performance of the equipment is a prerequisite for ensuring winding quality. The following core parameters should be given special attention:
Winding Speed Adjustment: The equipment must have a wide-range speed adjustment function and maintain stable operation at the set speed. Excessively high speeds may cause the wire to break due to excessive instantaneous tension, while excessively low speeds will significantly reduce production efficiency. A reasonable speed range should be pre-set based on the material and diameter of the wire.
Tension Adaptive Control: The tensioner should automatically adjust tension values based on different wire types (e.g., copper or aluminum) and diameter variations (0.1mm–2.0mm). Stable tension output prevents loose coil arrangement or excessive wire stretching, directly impacting insulation layer integrity and coil density.
Power System Protection: Use a multimeter to test the voltage stability at the power supply connection points, inspect the tightness of the terminal connections, and ensure there are no short circuits or loose connections. The phase balance of the three-phase power supply must also meet standards to prevent servo system failures caused by abnormal power supply.
II. Key Component Performance Testing
The precision and condition of core components directly determine the quality of equipment operation. Key inspection points include:
Servo drive system: Verify the brand parameters of the servo motor and use specialized software to read the positioning accuracy (should be ≤0.01mm) and response speed during motor operation. The pulse equivalent setting of the drive module must match the lead screw pitch to avoid cumulative errors.
Transmission mechanism precision: Use a laser interferometer to measure the straightness error of the guide rails (≤0.02mm/m), and observe the operational noise and lubrication status of the ball screws. If scratches on the screw surface or excessive guide rail clearance are detected, replacement must be performed promptly to ensure wire positioning accuracy.
Mold fixture adaptability: Check the concentricity of the fixture when clamping different-sized stators (deviation ≤ 0.03 mm). The clearance between the mold cavity and the stator core should be controlled within 0.05 mm. Regularly calibrate the pneumatic/hydraulic pressure of the fixture to prevent over-tightening causing winding displacement or over-loosening causing workpiece deformation.
III. Winding Precision Control Verification
Winding precision directly affects the electrical performance of the stator and must be verified through quantitative testing to ensure compliance:
Wire Arrangement Compatibility: Select straight, cross, or layered arrangements based on the width (typically 3 mm–10 mm) and angle of the stator slots. Verify through trial winding that the equipment can achieve uniform distribution of wires within the slots, with adjacent wire spacing errors ≤0.1 mm.
Slot parameter calibration: Adjust the slot distance based on wire diameter and the number of parallel wires (e.g., 2–6 parallel wires) to ensure precision. The minimum protective clearance must be greater than 1.2 times the wire diameter to prevent insulation layer damage during winding.
Turn count and slot count calibration: Pre-set the turn count parameters via the PLC control system (with an allowable error range of ±1 turn). After trial winding, use a turn count tester to verify the actual count. Simultaneously check whether the slot fill rate meets design requirements (typically 70%-85%) to avoid overfilling, which could cause difficulties in wire insertion.
IV. Safety System Inspection
Production must be safeguarded through both hardware configuration and institutional management:
Safety device effectiveness: Verify the response time of the emergency stop button (≤0.5 seconds) and whether the interlocking mechanism of the safety guard is functioning normally (the equipment stops immediately when the guard is opened). Infrared sensing protection must be installed in the equipment operating area to prevent limbs from entering hazardous zones.
Operational procedure compliance: Verify the implementation of operating procedures and employee training records, with a focus on high-risk processes such as mold changes and threading. Conduct regular emergency drills to ensure operators can proficiently use protective devices.
5. Detailed Management and Maintenance Inspection
Precision management is the key to the long-term stable operation of equipment:
Equipment stability monitoring: Use a spirit level to check the levelness of the machine body (error ≤ 0.1 mm/m). During operation, use a vibration detector to measure the amplitude (should be ≤ 0.05 mm). Abnormal vibrations should be investigated by checking the anchor bolts or transmission components.
Work Environment Control: The work surface must be kept free of oil stains and metal debris, with dedicated tool positioning slots provided. Environmental humidity should be controlled between 40% and 60% to prevent moisture-induced aging of electrical components.
Maintenance Plan Implementation: Verify maintenance records, focusing on critical items such as servo motor bearing lubrication (grease replacement every 500 operating hours), integrity of guide rail dust covers, and cleanliness of tensioners. Establish a list of spare parts inventory to ensure quick replacement.
Through the above multi-dimensional detailed inspections and continuous optimization, the motor stator winding machine can be effectively maintained in normal operating condition, providing reliable equipment support for high-quality stator production. Regular systematic inspections not only reduce failure rates but also extend equipment lifespan, creating greater production benefits for the company.
