Sections Of Stator And Anchor Windings Linear Winding Line Straight Lamination For BLDC PMSM And EV Motors WIND-ZR158-2

Winding Machine Application:

BLDC Stator Straight Lamination Winding machine is a trend for motor manufacturers who want to

produce high slot filling rate, small slot size, high performance electrical motors

Winding Machine Technical Data:

Wire diameter: 0.1mm to 0.8mm (AWG38 to AWG20)

Stator total length: Max 400mm

Stator stack height: Max 100mm

Slots no.: No limited

Turns no.: No limited

Winding speed: 600RPM (According to wire diameter size, stack height)

Airsource: 0.4~0.7MPa

Machine power: 8KW

3phase AC 380V 50~60Hz

Weight: about 900KGS

Dimension: 1100(W)*800(D)*2000(H)mm

Winding Machine WIND-ZR158 Competitive Advantages:

1. Japan design, Made in China

2. Two working station can wind 24SWG, 68 turns, 9 poles teeth stator in 1.5mintues (1.5minutes/2pcs)

3. Each segment winding coils displament neat and tidy, Perfect winding layer not only have neat and tidy

    appearance, also good quality with small resistance

4. Two station or three stations are with automatic loading device

5. Cycle time of winding 1pc Stator Winding (winding requirements as below)

    1.5minutes/2pcs (2 working station), 1.5 minutes/3pcs(3working stations). For a stator each pole

requires 68 turns of wire winding. Winding will start from 1st terminal and wire will crimped into terminals

and then 1st Pole will be winded 68 turns of coil then the wire will go from back side of part to 4th pole ,

here again 68 turns clockwise and wire will move from back to 7th pole and again winding 68 turns of coil

winding and then crimping small terminal.

Straight Lamination Stack Winding Machine Feature:

1. Through the winding needle up and down movement and the rotation of the lamination stack iron core,

     any track can be wound. Therefore, by changing the product winding program, corresponding windings

    with different core stack thickness and different turns number of core poles can be setted easily

2.  Human-machine dialogue can make sure the operation mode and maintenance easier

3.  Spiral wire turns no. cripmed into terminal can be arbitrarily setted and stop at any location 360°,

     As a result, It is simple and convenient to place bridge wire and shorten the overall cycle time.

     Improve production efficiency

4. During winding, the number of coils in each layer can be flexibly changed to realize different of product

    types layer.

5. Since the copper wire grooving operation is performed with high-performance Yaskawa control system

     and Yaskawa servo motor, the stability of the position of the enameled wire in the slot can be ensured

     and therefore shorten the winding time.

6. Manual or automatic robot hand feeding methods can be selected.

    Automatic loading and unloading can realize complete automated production of production lines,

    saving labor costs for motor manufacturer customers in mass production.

7. All units of the winding equipment have been fully standardized, and the toolings are easy to replace 

    The overall winding machine maintenance is more simple and convenient.

Example There are 9 poles/teeth.

Winding series :

1st pole-4th pole-7th pole

2nd pole-5th pole-8th pole

3rdpole-6th pole-9th pole

Wire : 24SWG DUAL COAT

Winding Machine Main Configuration:

In BLDC Winding Machine, there are two option, one is scew rod, the other is belt.The usage of the two

device is different: The application of the screw is to convert the rotary motion through the nut to the

linear motion. The application of the belt drive is to transfer rotary motion, change the rotation direction,

and change the speed ratio. Screw drive, good steel, can transmit large torque, accurate position, easy to

produce impact vibration when frequent commutation. Belt transmission, smooth transmission, elimination

of vibration, easy to throw away under heavy load. One, ball screw Ball screw is an ideal product that

converts rotary motion into linear motion or converts linear motion into rotary motion. Ball screw consists

of screw, nut and ball. Its function is to convert rotational motion into linear motion, which is the further

extension and development of ball screws. The significance of this development is to change the bearing

from rolling motion to sliding motion. Due to the small frictional resistance, ball screws are widely used in

various industrial equipment and precision instruments.

Ball screw is the most commonly used transmission element in power tools and precision machinery. Its

main function is to convert rotational motion into linear motion, or to convert torque into axial reversal

force, simultaneously with high precision, reversibility and high The characteristics of efficiency.

Ball screw features:

1. No backlash, high rigidity

Ball screw can be added to the pressure, because the pre-pressure can make the axial clearance to a

negative value, and then get a higher rigidity (ball screw through the ball to give pressure, in the actual

use for mechanical devices, etc., due to the ball The repulsive force can increase the rigidity of the wire

portion).

2. High-speed feed may

The ball screw can achieve high-speed feed (motion) due to its high efficiency of movement and low heat

generation.

3. High-precision guarantee

The ball screw pair is produced consistently with the world's highest level of machinery and equipment

manufactured in Japan. In particular, the temperature and humidity are strictly controlled in the factory

environment for grinding, assembling, and inspecting various processes, due to perfect quality

management. The system ensures full accuracy.

4. Compared with the sliding screw, the driving torque is 1/3

Since there are many rolling balls between the screw shaft of the ball screw pair and the nut, the higher

the movement efficiency can be obtained. Compared with the previous sliding screw pair, the driving

torque reaches 1/3 or less, that is, the power required to achieve the same movement result is 1/3 of that

of the rolling screw pair. It is helpful to save electricity.

5. Micro feed may

Since the ball screw pair uses the ball motion, the starting torque is very small, and no creeping

phenomenon such as sliding motion occurs, and accurate micro-feeding can be guaranteed.

Second, the  timing belt is an endless belt with steel wire rope or glass fiber as the strong layer and

covered with polyurethane (polyurethane timing belt) or neoprene rubber (rubber timing belt). The inner

circumference of the belt is made into a tooth shape and meshes with the toothed belt pulley. When the

timing belt is driven, the transmission ratio is accurate, the force on the shaft is small, the structure is

compact, the oil resistance, the wear resistance is good, the anti-aging performance is good, the general

use temperature is -20°C-80°C, v<50m/s, P<300kw, i<10, also for low speed drives for drives that require

synchronization. The timing belt drive is composed of an annular belt with an evenly spaced tooth profile

on the inner peripheral surface and a wheel with a corresponding anastomosis. It combines the

advantages of belt drives, chain drives and gear drives. When rotating, power is transmitted by meshing

the teeth with the tooth grooves of the wheel. Synchronous belt drive has an accurate transmission ratio,

no slip, can obtain a constant speed ratio, smooth transmission, vibration absorption, low noise,

transmission ratio range, generally up to 1:10. Permissible line speeds up to 50M/S, delivering power from

a few watts to hundreds of kilowatts. High transmission efficiency, generally up to 98%, compact structure,

suitable for multi-axis transmission, no lubrication, no pollution, so it can work in places that are not

allowed to have pollution and work environment is harsh. This product is widely used in textile, machine

tools, tobacco, communications cables, light industry, chemical industry, metallurgy, instrumentation

equipment, food, mining, petroleum, automotive and other industries in various types of mechanical

transmission.

Characteristics of synchronous belt:

(1) Accurate transmission, no sliding during operation, and constant transmission ratio;

(2) Smooth transmission, with buffer, vibration reduction, low noise;

(3) High transmission efficiency, up to 0.98, significant energy saving effect;

(4) Easy maintenance, no lubrication, low maintenance cost;

(5) The speed ratio range is large, generally up to 10, the line speed can reach 50m/s, with a large power

    transmission range, up to several watts to several hundred kilowatts;

(6) It can be used for long-distance transmission with a center distance of up to 10m.

Third, different points

1. The application of the screw is to convert the rotary motion into a linear motion through the nut. The

application of synchronous belt transmission is to transfer rotary motion, change the rotation direction,

and change the speed ratio. The bar drive, with good steel, can transmit large torque, accurate position,

and easy to produce impact vibration when frequent commutation. Because of the no-clearance between

ball screw and nut, the accuracy of linear motion is high, especially in the frequent commutation without

clearance compensation. The friction between the ball screw and the nut is very small and it is very easy

to rotate. Belt transmission, smooth transmission, elimination of vibration, easy to throw away under heavy

load.

2. Because of no gap between the ball screw and the female screw, the precision is high when the linear

movement, especially when the frequent commutation does not need the gap compensation. The friction

between the ball screw and the nut is very small and it is very easy to rotate. The principle of the ball

screw wire is to convert rotational motion into linear motion and convert torque into axial reversal force. It

has characteristics such as high precision, reversibility and high efficiency, which is a leap for the linear

motion series.

3, the belt drive has a simple structure, smooth transmission, low cost and buffer vibration absorption

characteristics; ball screw and motor must be connected to the middle of the coupling to achieve flexible

connection. The timing belt can be directly connected to the motor output shaft with a synchronous wheel.

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