The working principle of the winding machine is to drive the skeleton movement through the rotation of the main shaft, and at the same time, the wire arranging mechanism guides the enameled wire to be tightly arranged according to the preset rule, realizing the automation winding of the electromagnetic coil.
1, Core Component System
1. Spindle system
Driven by servo motors, precise control of rotation speed and number of turns
Equipped with clamps or jigs to fix skeletons of different shapes (circular/square/irregular)
The mainstream models have a speed range of 200-3000rpm and a torque accuracy of ± 0.5%
2. Cable laying system
Adopting a ball screw+linear guide structure, with a movement accuracy of 0.01mm
Stepper motor controls lateral displacement and maintains synchronous proportion with spindle speed
• Equipped with automatic reversing function, supporting layer winding/dense winding/cross winding and other modes
3. Tension control system
Magnetic powder brake provides adjustable tension of 0.1-25N
Install a tension sensor for real-time feedback adjustment, with a fluctuation range of less than ± 5%
Precision guide wheel assembly reduces friction damage to enameled wire
4. Numerical Control System
32-bit ARM processor, supporting storage of 100 sets of process parameters
7-inch touchscreen displays real-time parameters such as rotational speed, number of turns, and cable spacing
• Equipped with power-off memory, production statistics, and fault diagnosis functions
2, Workflow
1. Clamping stage: The pneumatic fixture automatically clamps the skeleton, and the detection device confirms the positioning accuracy
2. Parameter settings: Input parameters such as wire diameter of 0.02-2.0mm, target number of turns (maximum 99999 turns), and cable pitch
3. Winding treatment: The wire cutter automatically peels off the insulation layer of the enameled wire, and the static eliminator prevents the wire ends from scattering
4. Winding stage: The spindle and the wire arrangement mechanism move synchronously at a speed ratio of 1: (wire diameter+correction factor)
5. Termination control: Automatically stop after reaching the set number of turns, fix the wire tail with the wire clamping mechanism
6. Unloading process: The robotic arm automatically removes the finished product, and the defective product sorting device works synchronously
3, Technological evolution
• Precision improvement: The mainstream models have an error of less than ± 1 circle in the number of turns and a deviation of less than ± 0.02mm in the cable density
Efficiency optimization: The wire changing time has been shortened to 15 seconds, and it supports multi head synchronous winding (up to 16 heads)
• Material adaptation: Special control algorithms for special materials such as carbon fiber wires and Leeds wires have been added
IoT integration: Supports MODBUS/TCP protocol to achieve cloud based management of production data
4, Security protection
The equipment is equipped with a grating protection emergency stop device as standard, and the operating voltage is reduced to 24V safe voltage. The high-voltage winding area is set with double insulation isolation. Operators need to wear anti-static gloves and check the wear of the tensioner every shift.
