Working Principle Of Insertion Machine And Its Key Role In Motor Stator Production

The insertion machine is a key automation equipment in motor stator production, mainly used to accurately insert pre-wound coils (usually copper wires) into the slots of the stator core. It plays an important role in improving production efficiency, ensuring product quality and promoting motor manufacturing automation. This article will analyze the working principle of the insertion machine and its key role in stator production.

1. Working principle of insertion machine

The work of the insertion machine is based on the combination of mechanical automation and precision control. Its core task is to transfer the coil from the winding device and embed it into the stator slot. Its working principle can be roughly divided into the following steps:

Coil preparation and transmission

Before the insertion process, the coil is usually pre-wound by the winding machine to form a coil group of a specific shape and size. The insertion machine will move these coils from the winding station to the insertion station through a transmission mechanism (such as a conveyor belt or a manipulator) to ensure the accurate position of the coil.

Stator positioning and fixing

The stator core is placed on the fixture of the insertion machine, and the stability and alignment accuracy of the stator during the insertion process are ensured by positioning devices (such as clamping mechanisms or sensors). The opening of the stator slot is usually small, so the positioning accuracy directly affects the insertion effect.

Coil insertion process

The insertion machine uses special tools (such as insertion pins or push rods) to push the coils into the stator slots in sequence. This process is usually driven by a servo motor, with precision guides and pressure sensors to ensure that the coils are embedded in the slots with appropriate force and angle to avoid damaging the insulation layer or the core. During insertion, the insulating paper is usually pre-placed in the slot to protect the coil and prevent short circuits.

Shaping and inspection

After the insertion is completed, the insertion machine may be equipped with a shaping device to compact or adjust the coil ends to ensure that they meet the design requirements. Subsequently, visual inspection or electrical testing is used to check whether the coils are correctly embedded to avoid omissions or misalignment.

The entire process is controlled by a PLC (programmable logic controller) or CNC system, which can achieve high-speed, continuous automated operation while supporting the production needs of stators of different specifications.

2. Key role in motor stator production

In the production of motor stators, the insertion machine is not only a tool to improve efficiency, but also a guarantee of product quality and manufacturing consistency. Its key role is reflected in the following aspects:

Improve production efficiency

The traditional manual insertion of coils is time-consuming and labor-intensive, and it is difficult to meet the needs of large-scale production. The insertion machine can complete the coil embedding at a speed of several slots per second, significantly shortening the production cycle. For example, in the production of small and medium-sized motors (such as household appliance motors or automotive motors), an efficient insertion machine can replace multiple workers, greatly improving the efficiency of the assembly line.

Ensure product quality consistency

The insertion quality of the stator coil directly affects the electrical performance of the motor, such as magnetic field distribution, insulation performance and operating stability. The insertion machine ensures that the embedding depth and angle of each coil are consistent through precise force control and position adjustment, avoiding possible deviations in manual operation. This consistency is particularly important for mass-produced motors, which can effectively reduce the defective rate.

Reduce manual intervention and labor intensity

Coil insertion is a highly repetitive and technically demanding process. Manual operation is not only inefficient, but also easily causes worker fatigue and even occupational injury. The automated features of the insertion machine free workers from heavy labor, and only a small number of people are needed to monitor and maintain the equipment, thereby optimizing the allocation of human resources.

Support complex design and flexible production

As motor design becomes increasingly complex (such as the high slot fill rate requirements of new energy vehicle motors), the diversification of coil shapes and slot types has put forward higher requirements for the insertion process. Modern insertion machines can adapt to different stator specifications and coil types by adjusting parameters or replacing tools, and support flexible production. This is particularly critical for multi-variety, small-batch production.

Improve the integration of automated production lines

In the context of intelligent manufacturing, insertion machines usually form a complete stator automation production line with equipment such as winding machines, insulation paper insertion machines and shaping machines. Through seamless connection with the upper system (such as the industrial Internet of Things), the insertion machine can realize real-time data collection and feedback, further optimize the production process, and improve the overall automation level.

Summary

The insertion machine realizes the efficient conversion of coils from winding to embedding in stator slots through precise mechanical movements and automated control. Its working principle reflects the high integration of modern manufacturing technology. In the production of motor stators, it not only greatly improves production efficiency and product quality, but also promotes the intelligence and flexibility of the manufacturing process. As the motor industry develops towards high efficiency and high performance, insertion machines will continue to play a core role in automated production lines, providing important support for intelligent manufacturing in the Industrial 4.0 era.