Attention must be paid to the details of the motor
The impact of the electrical and mechanical properties of electromagnetic wires on motors goes without saying, and the level of attention from various motor manufacturers and customers is sufficient to explain everything. What is being discussed here is actually a common problem that motor manufacturers have not been able to effectively avoid. Quality hazards that have not been paid attention to often lead to quality accidents due to a lack of awareness.
Compatibility between single axis weight and equipment
Experienced winding masters have more or less experienced that when the electromagnetic spool is placed horizontally and moved relative to the supporting core, if the spool is relatively light, the electromagnetic spool will experience periodic collisions. If the electromagnetic wire coating has enough toughness, this hidden danger may be covered up.
In many cases, the wound coil has defects that are not visible to the naked eye, leading to incredible inter turn problems after entering the next process. Because it is inevitable to encounter situations where there are few turn to turn records from the wire embedding workers, and there is no sufficient reason, one can only reluctantly admit defeat. A worse situation is that, by chance, the process is inspected and electrical failures occur irregularly when it is sent to the customer's location. The main reasons for such hidden quality hazards are as follows:
Not seriously considering the matching problem between the single axle weight of the electromagnetic wire and the equipment speed;
The winding process causes uneven holes in the spool, making it difficult to detect the uneven tension on the electromagnetic wire during winding;
It is difficult to detect or detect situations where the electromagnetic wire is subjected to uneven tension, resulting in uneven wire diameter and paint peeling, unless the electromagnetic wire is seriously pulled apart. For situations where the spool is too heavy, similar issues may arise.
Friction between electromagnetic wire and spool end face
When the spool is placed vertically, there is no matching problem between the weight of the spool and the speed of the equipment, but if not properly protected, it can also pose quality hazards. A common situation is that there is friction between the electromagnetic wire and the end face of the spool, especially for cases where the end face is not smooth, which can easily cause damage to the coating of the electromagnetic wire. It is also impossible to completely detect and eliminate it during the later process inspection.
3. The spool is damaged or does not meet the requirements
This issue occurs frequently on wooden spools. Due to the separate structure between the end face of the wooden wire spool and the central axis, there may be varying degrees of gaps at the joint position. During electromagnetic wire winding, especially motor coil winding, some electromagnetic wires may penetrate the wire spool, causing the winding process to be blocked or directly penetrate the wire spool to break. This is a problem that electromagnetic wire manufacturers must face and solve.
4. Scattered arrangement of electromagnetic wires
Whether it is round or flat wire, if the arrangement is scattered, it will cause the spool to rotate unevenly during coil winding, and the electromagnetic wire will be subjected to uneven tension as a result. When the electromagnetic wire is damaged, the coil winding will be uneven, which is not conducive to later wire embedding and has a significant impact on motor performance.
Mismatch between 5 spools and equipment positioning
Usually, a positioning pin is used to fix the spool, ensuring that the electromagnetic spool and the winding equipment remain relatively stationary, so as to ensure the balanced rotation of the spool during the winding process. But in fact, there are often situations where the electromagnetic wire spool is very worn out, resulting in increased uncertainty factors in the diameter and position of the positioning hole, and the wire spool shaking during the coil winding process.
Damage of 6-wire mold to electromagnetic wire
For large-sized motor coils, the half turn length of the coil is relatively long, and the difference in the radius of rotation experienced by the electromagnetic wire during the winding process is particularly large, which exacerbates the degree of uneven force distribution during the electromagnetic wire winding process. Therefore, when setting the equipment speed, it should be considered that the speed should not be too fast and manual assistance should be used.
7 Layout issues during flat wire winding
If the arrangement of electromagnetic wires on the spool is good, it is easy to ensure their neatness during winding. Otherwise, the formed coils of the spool are poor, which can seriously affect the bonding effect and even cause the coil size to exceed the tolerance, making it impossible to embed the wire.
The unsuitability of all winding processes will be reflected to varying degrees in the embedding process and even affect the performance indicators of the motor. The key link in motor manufacturing is the manufacturing of the winding. Only by handling every detail well can the quality hazards of the motor be eliminated in the bud.
