Quality Control And Detection Technology Of Segmented Winding Machine

The segmented winding machine is the core equipment of the hairpin flat wire motor production line. It is widely used in the manufacturing of new energy vehicle motors. The quality of the coils it produces directly affects the performance and life of the motor. In order to ensure the high consistency and reliability of the coils, quality control and detection technology play a vital role in the operation of the segmented winding machine. This article will popularize the quality control and detection technology of the segmented winding machine for you, and help readers understand how to ensure production quality through scientific means.

Quality control starts with raw materials. The copper wire or flat wire used in the segmented winding machine must be strictly screened to ensure that the material is of high purity, no oxidation, no scratches, and the size meets the design specifications. Any minor material defects may cause the electrical performance of the coil to deteriorate, so the supplier needs to provide a detailed material test report and conduct a secondary inspection when entering the factory. During the winding process, the stability of the equipment and parameter settings are the key to quality control. The tension control system must be accurately adjusted to keep the wire tension uniform and avoid stretching deformation or relaxation. The synchronization of speed and angle is equally important. Modern winding machines are usually equipped with high-precision servo motors and closed-loop control systems. They adjust the operating status through real-time feedback to ensure that the coil shape is consistent with the design. Regular calibration of equipment should not be ignored. The wear of molds and fixtures needs to be checked and replaced in time to prevent quality problems caused by mechanical deviations.

Detection technology is the last line of defense for quality control and the core link to ensure product reliability. After the winding is completed, the visual inspection system takes the lead. High-resolution industrial cameras with image processing algorithms can quickly identify defects such as scratches, overlaps, and misalignments on the surface of the coil, with detection accuracy up to micron level. Dimension detection relies on laser measuring instruments to accurately measure the inner diameter, outer diameter, height and line spacing of the coil to ensure that each product meets the tolerance requirements. Electrical performance testing is the top priority. The resistance, insulation strength and withstand voltage performance of the coil are measured by high-precision testers to check potential short circuit or open circuit risks and ensure the stability of the coil under high load operation. In recent years, artificial intelligence technology has gradually been integrated into the detection process. The defect recognition model based on big data can more efficiently detect minor anomalies and greatly improve detection efficiency and reliability.

To further ensure quality, real-time monitoring and predictive maintenance have become a trend. The sensors equipped with the segmented winding machine can collect operating data such as vibration, temperature, and current, which can reflect the health status of the equipment through analysis. Abnormal fluctuations often indicate potential faults, such as bearing wear or motor overheating. The maintenance team can intervene in advance based on the data to avoid coil quality defects caused by equipment problems. In addition, the skill training of operators is crucial. Skilled operators can quickly adjust equipment parameters, accurately troubleshoot faults, and significantly reduce the impact of human errors on quality. Enterprises also need to establish a sound quality management system, record the test data of each batch of products, and form traceable archives to facilitate continuous optimization of production processes.

In short, the quality control and detection technology of the segmented winding machine is a multi-link collaborative system engineering. From raw material screening to equipment operation to finished product testing, every step requires excellence. Through scientific control methods and advanced detection technology, enterprises can produce high-precision and high-reliability coils, providing strong support for new energy vehicle motors. I hope that this popular science content will inspire you and help the industry develop with high quality!