The Process Flow And Precautions Of Motor Stator Winding Production

Motor stator winding is one of the core processes in motor manufacturing, and its quality directly affects the performance and life of the motor. This article will introduce the process flow of stator winding production in detail and summarize the key precautions to help readers better understand and optimize the production process.

1. Stator winding production process

Material preparation

Before stator winding, enameled wire, stator core, insulating materials, etc. need to be prepared. The specifications of the enameled wire (such as wire diameter, insulation grade) must meet the design requirements, and the surface of the core should be free of burrs and oil to ensure the smooth progress of subsequent processes. Insulating materials (such as slot insulation paper and phase insulation) must be cut accurately to ensure consistent size.

Core pretreatment

Put the stator core into a special fixture, check whether the slot shape is regular, and insert insulating paper into the slot. The insulating paper needs to be flat and fit without wrinkles or damage to prevent damage to the enameled wire or short circuit during winding.

Winding operation

The winding is usually done by automatic winding machine or manual winding. The automatic winding machine needs to set parameters (such as the number of turns and coil span) to ensure that the coils are arranged neatly. Manual winding requires the operator to master the technique to avoid loose or crossed coils. During the winding process, the tension of the enameled wire must be kept moderate to prevent stretching or breaking.

Coil shaping and fixing

After winding, the coil needs to be shaped to fit the core slot tightly and fixed with a binding tape or insulating tape to prevent the coil from loosening. Be careful not to damage the enameled wire insulation layer during shaping.

Insulation treatment

Insert interphase insulation material between coils and between coils and cores to enhance insulation performance. Then, the varnishing or dripping process is carried out, and the stator is immersed or dripped in the insulating varnish. After drying, a uniform insulating protective layer is formed to improve moisture resistance and heat dissipation.

Inspection and testing

Finally, the stator winding is subjected to resistance test, insulation test and withstand voltage test to ensure that there are no short circuit, open circuit or leakage problems in the winding. Qualified stators will enter the next process, such as assembly or packaging.

2. Precautions during the production process

Material quality control

Enameled wire and insulating materials need to be strictly inspected to avoid the use of inferior materials that may cause winding failure. The core slot type needs to be clean to prevent impurities from affecting the insulation performance.

Winding accuracy

When winding, the number of turns must be accurate and the coils must be arranged neatly to avoid motor performance degradation due to incorrect number of turns or loose coils. Automatic winding machines need to be calibrated regularly, and manual winding requires enhanced training.

Insulation protection

The installation of insulating materials and the operation of enameled wires must be extremely careful to avoid scratches or wear. During the varnishing process, the temperature of the varnish liquid and the drying time must be strictly controlled to ensure that the insulation layer is uniform and free of bubbles.

Safe operation

When the winding machine is running, the operator must comply with safety regulations to prevent mechanical injuries. During the varnishing and drying process, attention must be paid to ventilation to prevent the accumulation of harmful gases.

Quality inspection

Self-inspection and mutual inspection are required after each process is completed, especially after winding and insulation treatment, professional equipment inspection is required to ensure the product qualification rate.

3. Summary

Motor stator winding production is a process with high technical content and rigorous requirements. The quality of the stator can be effectively improved through standardized material preparation, core processing, winding operation, insulation treatment and quality inspection. At the same time, paying attention to details and strictly controlling the precautions of each process can significantly reduce the failure rate in production and lay the foundation for the efficient operation of the motor. I hope this article can provide practical reference for relevant practitioners and help optimize the production process.