With the continuous advancement of intelligent manufacturing, many motor companies choose to run winding machines at high speeds in pursuit of higher production efficiency. However, too fast an operating speed often causes problems such as enameled wire breakage, which in turn has a negative impact on production efficiency and product quality. This article will explore in depth the characteristics of high-speed bldc stator winding machine, as well as the reasons and solutions for stator winding machines being prone to wire breakage when running at high speeds.

1. Features of High Speed Winding Machine

Stator winding machines are usually used to accurately wind insulating coils on the stator of the motor. High-speed winding machines can perform winding tasks at a faster speed. At the same time, the use of advanced control systems and precise mechanical mechanisms can ensure the accuracy and consistency of winding. It greatly improves production efficiency and meets the needs of large-scale production. However, when the speed of the winding machine is too fast, the stability of the equipment and the bearing capacity of the wire will be tested, and the most common one is wire breakage.

2. Causes of Copper Wire Breakage

• Uneven force on the wire: Under high-speed operation, the tensile force on the wire changes greatly instantly, which can easily lead to uneven force. In addition, the wires in different parts are subjected to different tensions, which can easily cause breakage at weak points.
• Improper tension setting: During the winding process, the setting of tension is crucial. If the tension is too high, it may cause the enameled wire to break, and the failure or quality problem of the tensioner will also affect the stability of the wire.
• Winding speed is too fast: In winding, each winding device has its upper speed limit. If the upper speed limit of the device is exceeded, the wire will be subjected to excessive tension during the winding process, which will cause the wire to break.
• Wire quality: The wire diameter and material of the enameled wire will also affect its performance at high speeds. For example, using an inappropriate wire diameter or material may cause the wire to be unable to withstand the tension at high speeds and break.
• Equipment configuration issues: The reasonable configuration of the winding machine directly affects its operating performance. If the servo motor and drive controller are of poor quality and the control is not precise enough, the wire may break when running at high speed.

In order to ensure that the stator winding machine can run smoothly during winding operations and reduce the occurrence of wire breakage, Holis takes the following solutions to effectively avoid the risk of wire breakage during the winding process:

• Optimize equipment configuration: Use advanced transmission system to reduce vibration of equipment when running at high speed and optimize the design of winding shaft, improve the control accuracy of equipment, and ensure uniform force on wire during winding.

• Adjust tension setting: Use high-quality tensioner and accurately adjust tension according to factors such as wire material, wire diameter and winding speed to avoid excessive or insufficient tension.

• Reasonably set winding speed: According to the performance of equipment and the characteristics of wire, reasonably set winding speed to avoid exceeding the upper speed limit of equipment. Under the premise of ensuring production efficiency, try to choose a more stable winding speed

• Improve equipment configuration: Use high-performance servo motor and drive controller to improve the control accuracy of equipment. At the same time, regularly maintain and service the equipment to ensure that its performance indicators are in good condition.

In short, high-speed stator winding machines play an important role in motor manufacturing, but they are prone to wire breakage during high-speed operation. As a provider of automotive motor winding assembly equipment solutions, Shenzhen HONEST has focused on motor winding equipment for more than 18 years. Through its in-depth analysis of the reasons for wire breakage during the winding process, and the adoption of corresponding solutions, it can effectively improve the stability of the stator winding machine's operation and the winding quality, avoid the occurrence of wire breakage and other problems, thereby improving production efficiency, reducing production costs, providing customers with better products and services, and providing strong guarantees for the efficient production of automobile and motor companies.