The rotor winding is the process of wrapping conductors around an object or device to create a component with specific shapes and properties. A rotor winding machine is a piece of equipment used for winding rotors in electric motors. Its working principle involves the automatic winding of wire materials by controlling the movement of the wire head and winding blade. It can efficiently and accurately complete the winding work on motor rotors, enhancing production efficiency and product quality.
Control Principle of the Rotor Winding Machine
The automatic rotor winding machine is a device used to wind electric motor rotors. Its control principle mainly encompasses two aspects: the mechanical transmission system and the electrical control system.
The mechanical transmission system is the core part of the rotor winding machine, facilitating precise winding of the rotor. Typically, the main mechanical components of a winding machine include the rotor positioning device, winding frame, slider, and main shaft. The rotor positioning device secures the rotor with clamps to ensure the accuracy of the winding. The winding frame supports the coils, allowing them to be evenly wound around the rotor. The slider controls the position and speed of the winding through the transmission of the screw rod, ensuring the precision of the winding.
The electrical control system is the core part of controlling and regulating the mechanical system. It consists of components such as PLCs (Programmable Logic Controllers), frequency converts, and servo motors, primarily used to control and adjust the winding speed, angle, and position. The PLC serves as the control core, achieving control and regulation of various parts of the winding machine by reading sensor signals and user input signals. Servo motors are used to drive the slider, enabling highly precise control of the winding position and speed.
Trends in the Rotor Winding Machine Market
Rotor winding machines, as key equipment in the manufacture of electric motors, have shown the following development trends in 2024:
1.Automation: With technological advancements and the demand for increased production efficiency, the adoption of sophisticated sensors and control systems is propelling rotor winding machines towards a higher level of automation, thereby enhancing product quality.
2.Market Expansion: Driven by the rapid development of industries such as automotive electronics, the global winding machine market is expected to expand further. The expansion of market size and the increase in the number of manufacturing enterprises have led to fierce market competition. Companies need to improve their competitiveness through technological innovation and effective market strategies.
3.Energy Conservation and Environmental Protection Policies: Several countries worldwide have introduced various supportive policies related to environmental protection and clean energy, urging manufacturers to develop more energy-efficient and environmentally friendly equipment in response to the call for green production.
4.Policy Support: Against the backdrop of national efforts to revitalize the development of the intelligent equipment manufacturing industry, a favorable policy environment and market opportunities have been provided for the development of rotor winding machines.
In all, the rotor winding machine industry will continue to evolve towards high efficiency, intelligence, and environmental friendliness, continuously innovating and breaking through technologically.
Types of Rotor Winding Machines
A.Double Fork Rotor Winding Machine
The double fork rotor winding machine is a device designed for winding rotors. Its working principle involves symmetrical molds that protect the rotor core, which is then driven by an axis to the desired slot for winding. Once in position, the double fork mechanism winds the wire into the corresponding slot.
Advantages of HONEST Automation’s Double Fork Rotor Winding Machine
1.High Automation: Automated loading and unloading, operated by a single person, effectively saving labor and production time.
2.Efficient Material Utilization: Quality management during the winding process ensures efficient use of wire materials, achieving no wire ends and zero waste of copper wire, improving material utilization and saving production costs.
3.Multi-station Winding Machine: Equipped with four winding stations, precision control keeps the defect rate at 0.5%, ensuring production efficiency and product quality.
4.Large Capacity Program Storage: The built-in large capacity program storage function allows the machine to store winding programs for multiple products, with automation ports reserved to ensure equipment compatibility.
5.Multi-machine Linkage: Linking multiple machines can form a complete automated production line, achieving scaled production and further improving production efficiency.
6.Intelligent Alarm System: Equipped with a tension break alarm system that immediately notifies operations in case of abnormal conditions, allowing timely measures to prevent production interruptions.
B.4000A Rotor Precision Winding Machine
It is a high-performance automated winding equipment. The winding machine uses imported controllers for control, with X, Y, and Z-axis servo motors for wire hanging, R-axis servo motors for winding, and W-axis motors for pole changing, ensuring stable operation.
Features:
1.The machine automatically performs wire tail and head recovery actions, effectively enhancing the continuity of the production process and material utilization.
2.Multi-axis winding design, the machine is equipped with four winding heads for winding, with another four winding heads waiting for loading and unloading, increasing production efficiency.
3.High Flexibility: The machine design focuses on flexibility, making it easy to switch models and adapt to various winding methods to meet different customer production needs.
4.Intelligent Operation Interface: Equipped with an intelligent touch screen, providing a user-friendly operation interface, making program modification simple.
...
Maintenance and Care of Rotor Winding Machines
For machinery to operate stably and consistently over the long term, professional maintenance and care are essential. Here are some basic maintenance and care measures:
1.Daily Inspection: Before and after using the equipment, conduct a thorough check to ensure all components are correctly installed and show no signs of significant wear.
2.Electrical System Maintenance: Regularly inspect electrical connections to ensure there is no looseness or corrosion, preventing short circuits or connection failures.
3.Tension System Calibration: Periodically calibrate the tension system to ensure consistent and precise winding tension, guaranteeing the high quality of the coils.
4.Operator Training: Provide professional knowledge training for every production staff member to understand the operation standards and maintenance knowledge of the equipment, preventing damage due to improper operation.
Our rotor winding machines, known for their high compatibility and production efficiency, are complemented by our non-standard customization services. By designing specific solutions, we meet the diverse production needs of our clients. We offer comprehensive after-sales service, with a commitment to rapid response: technical consultation replies within 5 minutes, and quick resolution of complaints within 8 hours. Additionally, our engineers will visit the customer’s factory for on-site maintenance as needed, ensuring smooth production operations.
Established in 2007, HONEST Automation started with self-developed custom winding machines and has accumulated experience in the field of rotor winding machine technology. We possess the technical capability to provide high-performance, high-quality rotor winding machines to the global market. We listen to every customer’s product requirements and carry out non-standard customized designs to achieve a perfect match between equipment and needs.
If you need rotor winding machine, please feel free to contact us at any time. We will provide you with detailed equipment information and a preliminary quotation.
