1. Introduction to the Inner Winding Machine
Figure 1 shows a schematic diagram of an internal winding machine, which is mainly suitable for winding motor stator coils with a wire diameter of 0.1~1.5mm. Internal winding machines can be classified as follows according to different standards:
• According to the number of stations, stator winding machines are divided into: single-station, two-station, four-station, and six-station models.
• According to stator type, they are divided into: stator internal winding machine and stator external winding machine;
• According to the transmission method of the upper and lower shafts, they are divided into: upper and lower electronic cam type and upper and lower mechanical cam type;
• According to the form of up and down movement, it can be divided into: up and down moving simultaneously and up and down alternating.
Figure 1. Schematic diagram of winding machine.
Figure 2. Flow chart of the winding process of the inner winding machine
Figure 3. On-site diagram of the winding process at the inner winding machine.
Figure 4 Automatic cable laying process
2. Winding process of the inner winding machine
The winding process of the inner winding machine is shown in Figure 2, and the on-site diagram is shown in Figure 3.
For ordinary fine wires, it is sufficient to meet the number of turns required for winding. For thicker wires and wires with special winding process requirements, a precision winding function is required (Figure 4).
3. Winding principle of the inner winding machine
The inner winding machine is mainly composed of three shafts: upper and lower shafts, indexing shaft, and wire winding shaft. The main shaft drives the three shafts to run different cam curves, which work together to form the winding action process of the inner winding machine. The electronic cam architecture is shown in Figure 5.
Figure 5 Electronic Cam Architecture
4. Winding process algorithm
(1) Common wiring algorithm
The internal winding machine supports flexible switching between ordinary winding and precision winding; ordinary winding is mostly used for winding equipment with a relatively large number of turns and a wire diameter of 0.1~0.5mm; precision winding is mostly used for winding equipment with a relatively small number of turns and a wire diameter of 0.5~1.5mm.
Figure 6. Standard ribbon cable
Ordinary ribbon cables are used in applications where the coil has many turns, the wire diameter is thin, and the requirements for cable density are not high. The ribbon cables are laid out according to the set width, wire diameter, and total number of turns.
(2) Precision wiring algorithm
Precision wiring is used in applications with few turns, thick wire diameter, specific requirements for the number of turns in each layer of wiring, and high requirements for wiring density. The number of winding turns and feed rate can be set for each layer of each slot of the coil.
Figure 7 Precision cabling
When editing precision cabling, first select the number of slots. After selection, you can set the number of turns and feed for each layer in each slot. The number of turns and feed for each layer can be set differently. Modify each layer of a slot according to the customer's on-site process to meet the customer's process requirements.
Figure 8 Precision cable setup
(3) Linear interpolation algorithm
The stator winding production process requires positioning and winding of each axis; the linear interpolation function uses an interpolator to drive each axis to start and stop at the same time, which can facilitate the positioning of each axis.
Figure 9 Linear interpolation
(4) Foot-binding algorithm
The stator winding production process requires a foot-winding process; by using an interpolator and a spiral algorithm, two axes draw arcs while the other axis performs straight-line positioning to achieve the foot-winding function.
Figure 10 Foot wrapping function
(5) Cylinder control algorithm
In the stator winding production process, actions such as rotating the swing arm, clamping the stator, and cutting the wire with shears are required. By selecting the cylinder and its state, customers can flexibly choose the required number of cylinders and their corresponding states.
Figure 11 Cylinder Assembly
(6) Stop Angle Algorithm
In the stator winding production process, the winding command needs to have four stop angle settings (later it was opened to stop at any angle) to facilitate the hanging, winding, and passing of wires after the winding is completed.
Figure 12 Stop Angle
5. Features of winding technology
• Customize editing action logic
Since winding machines require different programs for different workpieces, operators need to be able to design programs flexibly. Delta's ASDA-M-R series servo drives provide a complete solution to this problem. In this solution, we use the HMI's row and column list function to allow customers to set the program design steps.
• Program management functions
The ASDA-M-R series tertiary platform supports program management functions, with 20 program spaces reserved. Each program supports a maximum of 500 steps, which is sufficient to meet the needs of winding customers.
• The program is simple and easy to learn.
Compared to the traditional CNC operating system G-code programming method of winding machines, the ASDA-M-R series is tailored to customer requirements and winding process needs.
Figure 13 System Interface Diagram
The custom winding machine requires functional blocks (winding instructions, circular interpolation, foot wrapping function, cylinder control, etc.), and the program editing is simpler and easier to learn, and is more in line with the operating habits of on-site employees.
6. Advantages of winding technology
• Faster winding speed
The maximum speed can reach 900~1200 turns/min, and the actual speed depends on the load of the structure and the product process specifications.
• Quick response
The ASDA-M-R series multi-tasking mechanism can perform 1ms synchronous communication programs, and the fast scanning cycle enables high-precision and high-efficiency equipment.
• Flexible winding process
The system features electronic cam synchronization and includes both standard and precision winding functions, meeting the diverse needs of different winding processes while ensuring wire routing accuracy.
• Three-stage platform programmable sequence
The ASDA-M-R series uses a row-column list function, and the three-stage platform can be programmed to achieve a CNC-like operating system, which can meet the needs of customized winding processes.
• Program management functions
The ASDA-M-R series tertiary platform supports program management functions, reserving space for 20 programs, each supporting a maximum of 500 steps to meet customers' winding process needs.
• Excellent performance
The main controller of the motor stator winding machine solution adopts Delta's integrated drive and control three-axis servo drive - ASDA-M-R series. It integrates drive and control, and has the functions of both PLC and motion controller. The efficient development platform and multi-tasking working environment ensure the control accuracy and operation stability of the equipment.
• High value of standalone products
The ASDA-M-R controller is a three-in-one intelligent servo controller, equivalent to three servo controllers + PLC + motion controller, resulting in high value for a single unit.
