厦门米特针式绕线机Needlewindingmachine,适用于马达绕线
2018-11-15 11:54阅读：
这是一种近几年发展起来的绕线技术： 针式绕线机 Needdle winding machine，
厦门米特开发的针式绕线机，可用于无刷电机的定子绕线、无刷电机的转子绕线，油泵电机的定子内绕机，以及其他各种电机的内绕或外绕。
型号：MTNR-01/02/04/06
的无刷电机转子绕线机外转子针式外绕机设备，适用于航模、医疗器械、家用电器、电动车等多个领域的无刷电机外转子绕线。采用双工位针式外绕设计，人机界面具有故障诊断、产量计存等功能，配备伺服电机控制系统实现产品绕制，可根据客户需求设定自动绕线、多线径绕线、自动分度、自动跨槽、绕线速度等参数设定；每次动作循环将绕制多个无刷转子，操作简单，生产效率高等特点。
型号：MTWR-01/02/04/06无刷定子针式内绕机特别适用于油烟机电机、卷发器电机、伺服电机、无刷家用电机、步进电机、风扇电机、、吊扇电机、无叶风扇电机，无刷电动工具，无刷医疗器械等各类直流无刷电机。定子绕线设备采用双工位同时自动绕线，自动抽头、自动挂线，自动夹线剪线，自动排线，自动过线。
Unlike the previous winding processes, the term needle
winding technology is not derived
from the type of wire placing, but rather from the geometric
structure of the wire guide
respectively the nozzle. The wire guide, which acts like a
needle, directly navigates along
the placement contour around the bobbin. Opposed to other
winding processes, the needle
winding technology
has longer nozzles, which are adapted to the part which is to be
wrapped.
Similar to flyer winding technology, the bobbin is typically
tightly clamped. Needle
winding systems, which clamp the bobbin but allow a
rotational motion, are an exception. A rotary motion of the part is
always necessary for wire placement. This is why there
are pivoting needle carriers. The wire is not placed by a
circular motion, but on a direct
course along the winding geometry. The termination of
individual turns, which depends
on the product geometry, is usually manufactured fully
automatically. This is why this winding process is very
cost-effective and reliable even for high numbers of poles. The
needle
winding technology is mainly used for products with thicker
wires and lower numbers of
turns. Hence it is opposed to the flyer technology, where
thin wires and high numbers of
turns can be processed economically
如果
For better
wire guidance, auxiliary tools may be used, as shown in Figure
3.62. Aside from guiding,
they also pre-shape the wire. In accordance with the Bauschinger
effect (Section 3.1.1), the
wire can be bent in the opposite direction more easily
A space the size of the nozzle diameter or the nozzle width has to
be left between neighbouring poles, which is a disadvantage. The
nozzle diameter or nozzle width is about three
times the wire gauge. By using oval nozzles or nozzles with a
trumpet-shaped opening, the
relation of slot width and wire gauge can be reduced. The space
between two neighbouring
poles can therefore not be filled completely. An exception to this
is guiding the wire outside
of the slot, in order to utilise the remaining winding space. In
this method, the precision
of the wire guiding depends on the residual guiding properties of
the wire. Currently, a
special type of needle winding technology is being developed for
the direct winding of
distributed windings for larger stators. A new kinematics for more
complex placing of the
connecting wires is illustrated in below Figure.
A space the size of the nozzle diameter or the nozzle width
has to be left between neighbouring poles, which is a disadvantage.
The nozzle diameter or nozzle width is about three
times the wire gauge. By using oval nozzles or nozzles with a
trumpet-shaped opening, the
relation of slot width and wire gauge can be reduced. The
space between two neighbouring
poles can therefore not be filled completely. An exception to
this is guiding the wire outside
of the slot, in order to utilise the remaining winding space.
In this method, the precision
of the wire guiding depends on the residual guiding
properties of the wire. Currently, a
special type of needle winding technology is being developed
for the direct winding of
distributed windings for larger stators. A new kinematics for
more complex placing of the
connecting wires is illustrated in below
Figure.
设备特点：
1.
这种内绕机通过驱动线嘴上下运动和铁芯摆动进行绕线。
2.
可调整每层绕线的线嘴高度，从而可以降低线包的高度。
3.
自动缠线头线尾，自动绕线，自动排线，自动转位，自动夹剪。
4.
采用伺服精准定位，绕线，排线，转位。
5.
有单头、双头或四头几种机型，也可根据客户产能要求定制更多绕线头。
Due to a variety of product categories, there
are many diff erent types of manufacturing
machines in needle winding technology.
Special types of needle winding have been established for the high
demand of diff erent motors with relatively thick wires and high fi
ll
factors. For the geometry of a stator it can
be crucial whether the stator blank is picked up
vertically or horizontally, and which dynamic
targets can be achieved .
Applications
One distinguishes between three areas of
application in needle winding technology. These
application areas comprise a product category with
externally grooved stators, internally
grooved stators and pole chain winding,
respectively. Needle winding technology is not
suitable for traditional circular, quadratic or
rectangular cylindrical single coils, as other
technologies work much more economically for these
types of coils.
Therefore, stator winding is of great importance in
needle winding technology. Similar
to flyer winding technology, all of the placement
motions for this process are executed by
the wire guide. However, the rotation does not take
place via a circular motion. Instead,
the wire is directly placed along the stator or the
circumference of the tooth. The resulting
dynamic requirements are a challenge for the
manufacturing machines and, in comparison
to other processes, limit the number of turns per
minute.
Pole chains are multiple, linearly arranged and
attached single-poles which are assembled to a stator after
winding. Due to the existing connection, the single-poles just have
to
be arranged as a circular stator
shape.
The vertical arrangement of stators is often limited in that
wires can horizontally be
placed more evenly in very long grooves from a dynamic point
of view. For very short
grooves and therefore short placing strokes, a mechanical cam
control or synchronized
servo drives are used for high winding speeds. For chain
winding, special needle winding
machines are designed, which are adapted to each winding task
in their systematic structure.
The basic setup of needle winding systems, including the
placing gear, can be standardised in most cases. This has certain
levels, depending on the number of simultaneously
manufactured stators and their size. This shows that even in
needle winding technology a
duplication or multiplication of wire guides can be
economically reasonable. The larger the
processed wire gauge is, the higher are the forces that are
applied, and the machine has to
be designed with a higher stiffness. Due to the high
utilization of manufacturing machines, they are often equipped with
exchangeable parts or sub-assemblies, in order to wind
different products. The limitations of stator manufacturing
are lying in the groove width
between the pole shoes, and therefore are defined by the
distance between stator teeth or
stator length.
Wire feeding and wire course to the wire feeder
Similar to the previous processes, the wire is pulled from a
supply spool and fed to the wire
guide via a wire tension control system. For winding of
externally grooved stators, which
are wound vertically, and chain winders, the wire supply is
often located outside the manufacturing machine (Figure 3.59). This
can prevent unnecessary diversions which would
have a negative impact on the wire quality. The control
systems are usually designed to a
certain wire gauge range and must be adapted to each winding
task.
The lubrication of enamelled copper wire has a very important
task in needle winding
technology. Since the friction forces which act on the wire
are reduced with the lubricant,
it should be carried along up to the wire’s actual placement
to protect both the tools and
the machine.
The wire guide or needle carrier
In needle winding technology, there are special requirements
for the wire guide. The needle
is often designed to be longer than in other winding
processes due to the handling deep
inside the pole shoe. The wire guide nozzle is referred to as
needle in this technology. The
inner diameter is adapted to the wire guide. It has a highly
polished surface and a significant influence on the winding
quality. The wire often exits the needle at sharp angles and
is at this point highly strained, just like the needle. To
terminate and place the wire on the
stator face side, the needle must be pivoted around an angle.
This is especially challenging
for internally grooved bobbins, as the stator determines the
installation space for the wire
guide. When winding tooth chains with linearly arranged pole
shoes, three phases can be
wound at the same time. Connecting by terminating after the
winding process is unusual
for pole chains, as this is done with other technologies
after rounding the stator. As multiplication of the wire guide is
possible in needle winding technology, multiple stators and
phases can be wound at the same time. An adaptation of the
other sub-assemblies of the
machine, however, must be taken into account. For all needle
winding processes the critical measure between the pole shoes must
be considered. This also has an impact on the
dimensions of the wire guide nozzle. Figure 3.60 shows the
design of the needle carrier.
Fixtures
When considering stator fixtures, different product
categories can be distinguished. Fixtures for externally grooved
stators grip inside the part. Due to the imbalance properties
of the part, they are comparable to those of turning parts,
but are not as critical because of
lower speeds. Accordingly, internally grooved parts are
gripped on the outer diameter, and
are therefore constructed more elaborately in most
cases.
After each winding, the stators are switched from one pole
shoe to the next via a switching gear or a CNC turning axis. A
rotational fixture designed as force-fit or form-fit must
generally be taken into account. Usually, product specific
fixtures are intended for manufacturing single-teeth, respectively
concentrated windings or stator chain windings. Initially, the
internally grooved stators are aligned linearly before later being
rounded. During
the winding process, they are lined up like a chain and
fixated on their circumferential surface, so that the pole shoe is
accessible from all directions necessary for winding. It should
be ensured that the parts which are to be wrapped are fixed
well, so that the force applied
by the placing is well absorbed by the tooth. To enable
convenient loading and unloading,
an easy clamping must be provided for both manual and fully
automated processes. These
special tools must also be of high manufacturing
quality.
Fully automated winding process
For product manufacturing with needle winding technology, the
wire is also fixated at a
starting point. This can be an external wire park pin or a
contacting post on the tool, or
the stator. The difference to other winding processes is the
processing of thicker wires.
In this process, the loose wire end has a relatively stable
shape due to its high stiffness,
which does not necessarily demand clamping between the
winding processes. Based on
the motion sequence during placement, the switching gear axis
can directly support the
operating procedure and take over the rotational motion, as
long as it is controlled by a
servo motor. To prevent the needle from touching the stator,
a precise synchronisation of
the rotational motion and the stroke motion is necessary.
Influencing factors for the maximum winding speed are, among
others, the needle stroke, the stator rotational angle defined by
the number of poles, the wire gauge, and the slot width. A special
role is assigned to
the pitch angle of a stator with pitched grooves. Both servo
motoric rotational axes and a
communication between two axes is necessary in order to
ensure a proper motion profile.
This also has an impact on the manufacturing times. Since the
distribution of the stroke
length to the rotational motion of the stator is significant,
and the servo drives must constantly reverse in order to generate
the reversed needle motion, a crank disk can be used.
The initiation of the stroke motion is transferred to the
crank disk via a rotational motion,
which should contain a stroke adjustment, in order to achieve
the benefits of a sinusoidal/
semi-circular motion sequence. Depending on the design, up to
2,500 strokes per minute
can be achieved. As the wire guide nozzle can be moved
freely, the wire termination on the
contact point can be performed with an additional pivoting of
the nozzle. Similar to traditional linear winding technology, a
contact pin or a lug is used to connect the individual
poles with either a star or a delta connection. During the
process, the combined weight of
wire guide and needle carrier may lead to undesired
vibrations due to the axis acceleration. This, in turn, can
influence the winding quality negatively. Accordingly, alternative
materials from steel are considered. By using the needle
winding technology it is possible
to manufacture whole sub-assemblies, including stator coils,
wiring, and contacting on
a single machine. As opposed to insert technology, and aside
from the not fully utilized
space between the poles, it is possible to wind motor coils
on lower lamination stacks with
smaller winding heads, which have a good fill
factor.
Wire placement
Nearly every pole shoe has a rectangular or quadratic coils
shape. Consequently, the winding speeds of this winding technique
are constantly changing and the wire tension control
is expected to balance the speed variations effectively. The
acceleration and deceleration of
the wire guide and the different forces on the stator
therefore require firm tool fittings and
stability of the individual axes. This is a pre-requirement
for the manufacturing of high
quality windings. The wire processing on small stators is
usually based on concentrated
windings around the individual pole shoes. Therefore, it is
significantly different to the
processing of windings with insert technology, for which the
winding can be inserted over
multiple teeth. The placement does not necessarily follow
from one stator tooth to the
other. Different winding topologies are possible as well.
The wire is bent after exiting the wire guide nozzle, since
the wire guide nozzle moves
past the placement contour sideways rather than with the
front, like in other processes.
This leads to a wire diversion of up to 90° and significantly
strains the wire itself as well
as the nozzle. It is often difficult to wind enamelled copper
wires with larger gauges for
small components with an orthocyclic scheme. The extreme
bending of the wire before
the placement is the reason for an undefined deformation
geometry from the residual .
stresses. However, an ordered layer structure can be realised
for large wire gauges with
a precise manufacturing machine, using the properties of
cylindrical bobbins. For better
wire guidance, auxiliary tools may be used, as shown in
Figure 3.62. Aside from guiding,
they also pre-shape the wire. In accordance with the
Bauschinger effect (Section 3.1.1), the
wire can be bent in the opposite direction more
easily.
A space the size of the nozzle diameter or the nozzle width
has to be left between neighbouring poles, which is a disadvantage.
The nozzle diameter or nozzle width is about three
times the wire gauge. By using oval nozzles or nozzles with a
trumpet-shaped opening, the
relation of slot width and wire gauge can be reduced. The
space between two neighbouring
poles can therefore not be filled completely. An exception to
this is guiding the wire outside
of the slot, in order to utilise the remaining winding space.
In this method, the precision
of the wire guiding depends on the residual guiding
properties of the wire. Currently, a
special type of needle winding technology is being developed
for the direct winding of
distributed windings for larger stators.
适用产品：
鱼缸电机 BLDC电机 直流风扇电机 滑动门电机
车载用旋转变压器 冰箱用风扇电机 空调用风扇电机 空调用压缩机 冰箱用压缩机 车载用风扇电机 油泵电机 水泵电机
推拉门电机
设备工序说明：
1、手工放骨架
2． 绕线说明
3、主轴旋转转一个极，重复以上动作，完成所有的极。
技术参数：
适用线径
φ0.4--φ1.3
铁芯外径
Max 200mm
铁芯内径
Min
28mm
铁芯积厚
Max 70mm
线嘴运动速度
Max.
2,500RPM
控制轴数
4 轴
空气压力
0.45--0.65Mpa
电 源
AC 380V
50/60HZ
外型尺寸
约1050W*800L*1800H
重 量
约800kg
