Winding configurations and advantages of motors for unmanned aerial vehicles

The motor on a drone is the core component of its propulsion system, responsible for driving the propellers to rotate and generating lift and thrust. Also known as an electric motor, it converts electrical energy into mechanical energy, enabling the drone to perform actions such as take-off, hovering, landing and movement. The power and efficiency of the motor directly affect the drone’s performance and flight time. So, what are the common winding methods for brushless motors?

1. Fly-spool winding: This method is commonly used for motors with outward-facing slots in the stator, such as those found in model aircraft, self-balancing scooters, electric scooters, new energy vehicles, rotary transformers, fan stators, gyro scooters, cooling fan stators, crop dusting drones, and various other types of externally wound stators. Once all parameters have been set, the copper wire is wound by the high-speed rotation of the flying fork. The guide plate plays a supporting role, securing the copper wire into the slots. Through the forward and backward movement of the die head, the wire is arranged in an orderly manner, ensuring precise winding in each slot.

2. Needle winding: This method is commonly used for motor stators with inward-facing slots, such as those found in power tools, water pumps, stepper motors, vacuum cleaner motors, barrier gates and winches. Once the parameters are set, the tungsten steel wire guide moves in tandem with the wire; through the vertical and horizontal movement of the guide needles, precise wire arrangement and winding are achieved.

Both winding methods have their own advantages and specific applications. Standard models are available, and customised solutions can also be provided. In terms of price, external winding is generally more cost-effective, whilst internal winding is more expensive. It is usually immediately apparent which machine is suitable for a given sample; select a winding machine with the appropriate workstations based on your specific production requirements.

Brushless DC motors primarily consist of a magnetised rotor, a stator with multi-phase coil windings, and a Hall-effect position sensor (optional). The operating principle is based on electromagnetic induction and magnetic field interaction. The stator comprises multiple coils, typically wound with insulated wire and fixed to the motor housing. The rotor consists of permanent magnets, usually arranged in a specific configuration. Brushless motors must be controlled by an ESC, which converts the DC power from the battery into three-phase AC power and regulates the motor speed according to signals from the flight controller.