By leveraging the powerful axis control capabilities of the Delta CNC system and the fast, precise motion response of the Delta servo system, the working efficiency of the winding machine has been greatly improved. This article mainly introduces the functional requirements of the CNC stator winding machine, as well as the system operation interface and I/O planning. 1 Introduction The current market for winding machines is vast, with a wide variety of types, including parallel winding machines, toroidal winding machines, stator and rotor winding machines, and textile winding machines. This article mainly introduces the equipment built using the Delta CNC system and servo products: the CNC stator winding machine. Its biggest feature is that it can automatically change the winding direction, producing neat coils with accurate turn counts. It is easy to operate, saves labor, increases output, and produces high-quality products. Its winding, wire laying, stopping, and slot changing are all executed automatically according to the program. The wire laying width is adjustable, and the turn count is accurate. It has a high production speed and saves a significant amount of wire. The following outlines how to integrate this solution using Delta's CNC and Delta's servo systems. 2. Technical and Precision Requirements The customer originally used a PLC + servo control system for the entire machine. However, the yield rate of the processed products was low, and some functions could not be implemented, failing to meet market demands. Therefore, they requested the development of a CNC stator winding machine, requiring the control system and servo to meet the following conditions: 2.1 Mechanically, a three-axis control coordinate system is required for the servo motion axes. Specifically, the X-axis (winding axis) uses a servo motor to directly drive a 4mm pitch ball screw, performing linear motion on the connecting worktable; the Y-axis (flying fork axis) uses a servo motor to drive a 1:2 gearbox for indirect transmission, performing 360-degree circular motion; and the Z-axis (indexing axis) uses a servo motor to drive a 1:9 gearbox for indirect transmission, performing 360-degree circular motion. These three axes must be able to move in tandem. Furthermore, for the flying fork axis, the mechanical load inertia changes significantly during movement due to variations in winding speed. This requires the servo system to possess excellent stability, responsiveness, and adaptability to load changes. [IMG=Figure 1 CNC stator winding machine appearance]/uploadpic/THESIS/2007/11/200711160951528005427.jpg[/IMG] Figure 1 CNC stator winding machine appearance [IMG=Figure 2 System architecture]/uploadpic/THESIS/2007/11/2007111609545691218J.jpg[/IMG] Figure 2 System architecture 2.2 Accuracy Requirements Mechanical zeroing accuracy: wire guide shaft 0.005mm Flying fork shaft +/-1 degree Indexing shaft +/-1 degree Positioning accuracy: 0.02mm +/-1 degree Requirements The control system and servo system should have detection feedback to ensure the accuracy of mechanical movement. 2.3 The CNC control system requires not only accurate winding turns for the stator winding machine but also uniform wire density, necessitating interpolation calculations between at least two axes to achieve联动 (interlocking/coordination). The screen should be freely customizable; the system should facilitate easy transmission of machining programs to the customer, and allow for NC program editing and storage. The control system should provide a D/A port for constant tension control. Additionally, the customer requests an extra axis for future use. 3. Feasibility Analysis of the Solution Based on the analysis of mechanical design and control technology requirements, a control architecture was determined to be a Delta Electronics general-purpose four-axis H4-4 host computer control system + three Delta B-series AC servo ASD-B sets for slave computer control. The specific analysis is as follows: 3.1 Main features of Delta Electronics H4 general-purpose CNC [IMG=Figure 3 Start-up screen]/uploadpic/THESIS/2007/11/2007111610003762583H.jpg[/IMG] Figure 3 Start-up screen [IMG=Figure 4 Origin mode screen]/uploadpic/THESIS/2007/11/200711161002296875923.jpg[/IMG] Figure 4 Origin mode screen [IMG=Figure 5 Manual mode screen]/uploadpic/THESIS/2007/11/2007111610375068408Q.jpg[/IMG] Figure 5 Manual mode screen (1) Independent servo interface, which can realize multi-axis linkage. (2) Voltage command type (V-Command) servo interface with a minimum resolution of 0.001mm, which can be used with a grating ruler or rotary encoder to achieve closed-loop and semi-closed-loop control, meeting the accuracy requirements. (3) Maximum response speed of 500KPPS encoder feedback, which can meet the requirements of rapid positioning. (4) The controller has 512K of memory space, which can store 1000 NC machining programs. With a standard CNC keyboard, machining programs can be easily written. (5) Through CNC simple I/O control commands and built-in PLC development, auxiliary functions can be flexibly realized. (6) Built-in programmable PLC, standard configuration is 24 INPUT/16 OUTPUT, and can be increased to a maximum of 32 INPUT/32 OUTPUT. (7) 2 sets of D/A outputs and 2 sets of A/D inputs, which can fully meet the control requirements of constant tension. Through comparative analysis, it can fully meet the control requirements of the host computer. 3.2 Main features of Delta AC servo system (1) It has multiple control modes and can be flexibly matched with the upper controller, with wide application. (2) It has position P-CURVE and speed S-CURVE functions. (3) Robust control mode, the system can still maintain excellent performance when the load inertia changes over a wide range. (4) Rich software functions, convenient for users to debug. Through comparative analysis, Delta AC servo system can fully meet the control requirements as a lower controller. Through analysis and calculation of mechanical structure, load inertia and output torque, the following are selected: ASDB 400W*1 and ASDB 750W*2 as lower controllers. 4 Functional design 4.1 System architecture (as shown in Figure 2) 4.2 Appearance and functional requirements The winding machine has multiple functions such as origin finding, jog mode, single mode, automatic mode, programming mode, parameter setting, and test output point function. (1) System Operation Interface Planning The operation interface is mainly divided into the following functional blocks: Startup screen as shown in Figure 3: After the system is powered on, it enters this screen. At this time, it is in standby mode, and the bottom row of the screen is the function display area. Origin mode as shown in Figure 4: When the screen is in origin mode, press the X, Y, and Z function keys respectively, and then press the start key. You can return to the origin in sequence; or you can press the X&Y&Z function keys, and then press the start key to return to the origin simultaneously for all three axes. Manual mode as shown in Figure 5: After entering manual mode, you can press the X, Y, and Z axis keys respectively, and then press to move forward or backward or reverse. The speed value can be set. Automatic mode as shown in Figure 6: In automatic mode, when the program is running, you can observe the current movement of each axis, the current machining program number, the parameter group number, the current machining stage, and the time required to complete a workpiece. You can also pause the program and execute it step by step according to your needs. [IMG=Figure 6 Automatic Mode Screen]/uploadpic/THESIS/2007/11/20071116104053843177.jpg[/IMG] Figure 6 Automatic Mode Screen [IMG=Figure 7 Alarm Screen]/uploadpic/THESIS/2007/11/20071116104304110716.jpg[/IMG] Figure 7 Alarm Screen [IMG=Figure 8 Parameter Setting Screen]/uploadpic/THESIS/2007/11/2007111610443537072N.jpg[/IMG] Figure 8 Parameter Setting Screen [IMG=Figure 9 Emergency Stop Release Action Flowchart]/uploadpic/THESIS/2007/11/2007111610533486667X.jpg[/IMG] Figure 9 Emergency stop release action flow chart [IMG=Fig.10 Main program control flow chart]/uploadpic/THESIS/2007/11/2007111610571316400V.jpg[/IMG] Fig.10 Main program control flow chart Alarm screen is shown in Fig.7: When an alarm fault occurs, the system will automatically stop running, and the screen will enter the alarm screen, and the fault alarm number will be highlighted. Only after the fault is eliminated can other actions be performed. Parameter setting function is shown in Fig.8: Under this function, the customer will set the corresponding parameters according to the actual workpiece needs and save them under the current parameter group. A total of 12 workpiece parameters can be saved, and there are 6 pages of screen parameters that can be set. The customer can also read out the parameters according to their own needs. (2) Implementation of important functions Emergency stop: When the equipment is in use, if any problem occurs, press the emergency stop to prevent the occurrence of dangerous actions. After releasing the emergency stop, the system will perform the return to position according to the prescribed action procedure. Fig.9 is the action flow chart. The program is shown in the main control program. Figure 10 illustrates the implementation of the read/write parameter function: Customers can set corresponding parameters according to the actual workpiece specifications and store them in the controller. Currently, 12 workpiece parameters are available, allowing customers to directly read the parameters. The program is shown in the main control program. Implementation of pole winding and layer winding functions: Different workpieces require different winding methods. Currently, there are two methods: pole winding and layer winding. Pole winding automatically lays out the wires and layers according to the total number of turns for each pole until winding is complete. Layer winding requires that the number of turns for each layer be set, dividing the workpiece into multiple layers based on the total number of turns. This method is generally used for thicker wire diameters. The program is shown in the main control program. Workpiece program compilation: Since the number of poles, winding method, and the action sequence of each cylinder may differ for each workpiece, it is required to be written using G-code. This saves unnecessary steps and significantly reduces time. The number of workpiece programs that can be stored can reach over 900, fully meeting the processing needs of all workpiece types. 4.3 I/O Point Planning and Wiring (as shown in Figures 11, 12, and 13) 4.4 Main Control Program 00000 (JR1) N01 G65 L01 P#160 A1 N05 G04 X2.2 G65 L50 G65 L82 P10 A#168 B1 G12 P13 G65 L80 P20 N10 G12 P14 N20 M104 G12 P15 M98 P700 G12 P8 G01 W#162 F#4 M98 P300 M210 G01 X#5 F8000 G12 P12 M98 P801 G04 X1.0 M98 P800 M209 G12 P8 G01 W#162 F#4 M98 P300 M210 G01 X#5 F8000 G12 P12 M98 P801 G04 X1.0 M98 P800 M209 G12 P8 G01 W#162 F#4 M98 P300 M210 G01 X#5 F8000 G12 P12 M98 P801 G04 P300 M210 G01 X#5 F8000 G12 P12 M98 P801 M98 P301 M30 00001 (CR1) N01 G65 L01 P#160 A1 N05 G04 P20 N10 G12 P14 B500 N20 M104 G12 P15 M98 P700 G12 P8 G01 W#162 F#4 M98 P300 G01 X#5 F5000 M98 P802 G04 X1.0 M98 P800 M209 G12 P8 G01 W#162 F#4 M98 P300 G01 X#5 F5000 M98 P802 G04 X1.0 M98 P800 M209 G12 P8 G01 W#162 F#4 M98 P300 G01 X#5 F5000 M98 P802 G04 X1.0 [IMG=Figure 11 Input Signal Table]/uploadpic/THESIS/2007/11/2007111611051397431C.jpg[/IMG] Figure 11 Input Signal Table [IMG=Figure 12 Output Signal Table]/uploadpic/THESIS/2007/11/2007111611090495328B.jpg[/IMG] Figure 12 Output Signal Table M98 P800 M209 G12 P8 G01 W#162 F#4 M98 P300 G01 X#5 F5000 M98 P802 G04 X1.0 • • • M98 P800 M209 G12 P8 G01 W#162 F#4 M98 P300 G01 X#5 F5000 M98 P802 G04 X1.0 M98 P301 M30 00888 G01 X0. F5000 M205 G12 P20 M212 G12 P99 M211 G12 P97 M210 G12 P12 M209 G12 P8 M208 G12 P10 M205 G12 P20 M206 G12 P22 G65 L50 G01 Z0. F10000 G04 X1.0 M204 G12 P16 M207 G12 P18 G01 Y0. F10000 M30 [IMG=Figure 13 Servo and Other Electrical Wiring Diagram]/uploadpic/THESIS/2007/11/2007111611135683322I.jpg[/IMG] Figure 13 Servo and Other Electrical Wiring Diagram [IMG=Figure 14 Finished Product Image]/uploadpic/THESIS/2007/11/2007111611151636411Y.jpg[/IMG] Figure 14 Finished Product Drawings: 00900 G65 L03 P#22 A#21 B1 G65 L04 P#23 A#22 B300 G65 L02 P#24 A#23 B1001 G65 L02 P#25 A#24 B30 G65 L02 P#26 A#25 B40 G65 L07 P#1 A#900024 B20 G65 L07 P#300 A#900025 B36 G65 L07 P#505 A#900026 B150 M30 00901 G65 L03 P#22 A#21 B1 G65 L04 P#23 A#22 B300 G65 L02 P#24 A#23 B1001 G65 L02 P#25 A#24 B30 G65 L02 P#26 A#25 B40 G65 L07 P#900024 A#1 B20 G65 L07 P#900025 A#300 B36 G65 L07 P#900026 A#505 B150 M30 00300 M107 G12 P17 M105 G12 P19 M106 M108 G12 P9 M109 G12 P7 M99 00301 M205 G12 P20 M206 G12 P22 G01 U-#7 F1500 M209 G12 P8 G01 Z0. F10000 M210 G12 P12 M111 G12 P96 M212 G12 P99 M211 G12 P97 G01 X0. F10000 M208 G12 P10 M204 G12 P16 M207 G12 P18 M99 00700 G65 L50 G65 L04 P#161 A#160 B5 G65 L02 P#161 A#161 B500 G65 L01 P#162 A#900161 G65 L02 P#161 A#161 B1 G65 L01 P#155 A#900161 G65 L02 P#161 A#161 B1 G65 L01 P#165 A#900161 G65 L02 P#161 A#161 B1 G65 L01 P#11155 A#900161 G65 L02 P#161 A#161 B1 G65 L01 P#166 A#900161 G65 L86 P200 A#165 B0 G65 L86 P200 A#155 B0 M99 00750 G01 U#130 V#121 F#165 G01 U-#130 V#121 M99 00800 M110 G12 P11 G01 U-#6 F5000 M209 G12 P8 G65 L50 G65 L04 P#161 A#160 B5 G65 L02 P#161 A#161 B500 G65 L01 P#162 A#900161 G65 L02 P#161 A#161 B1 G65 L01 P#155 A#900161 G65 L02 P#161 A#161 B1 G65 L01 P#165 A#900161 G65 L02 P#161 A#161 B1 G65 L01 P#11155 A#900161 G65 L02 P#161 A#161 B1 G65 L01 P#166 A#900161 G65 L86 P200 A#165 B0 G65 L86 P200 A#155 B0 M99 00801 (JR) G65 L50 G65 L05 P#120 A#2 B#3 G65 L04 P#121 A#120 B360000 G65 L04 P#122 A#155 B#3 G65 L05 P#123 A#122 B#2 G65 L05 P#124 A#123 B2 G65 L04 P#125 A#123 B#120 G65 L03 P#126 A#155 B#125 G65 L03 P#127 A#155 B2 G65 L04 P#128 A#127 B#3 G65 L04 P#129 A#127 B360000 G65 L04 P#130 A#3 B#120 G65 L04 P#131 A#126 B#3 G65 L04 P#132 A#126 B360000 G65 L03 P#140 A#123 B1 G65 L05 P#141 A#140 B2 N35 G65 L82 P40 A#123 B0 M210 G12 P12 G01 U-#128 V#129 F#165 G01 U#128 V720000 G01 X#5 Y0. F5000 G01 V#166 F10000 G65 L80 P80 N50 G65 L82 P60 A#123 B2 M210 G12 P12 G01 U-#130 V#121 F#165 G01 U#130 V#121 G01 U-#131 V#132 G01 X#5 Y0. F5000 G01 V#166 F10000 G65 L80 P80 N60 G65 L23 P#133 A#123 B2 G65 L81 P70 A#133 B0 M210 G12 P12 G01 U-#130 V#121 F#165 M98 P750 L#141 G01 U#131 V#132 F#165 G01 X#5 Y0. F5000 G01 V#166 F10000 N80 M112 G12 P98 G65 L02 P#160 A#160 B1 M99 00802 (CR) M210 G12 P12 G65 L50 G65 L81 P80 A#301 B0 G65 L04 P#400 A#301 B360000 G65 L03 P#401 A#2 B#300 G65 L03 P#402 A#401 B#302 G01 U-#300 F2500 G01 U-#402 V#400 F#165 G01 U-#302 F2500 G65 L81 P80 A#304 B0 G65 L04 P#403 A#304 B360000 G65 L03 P#404 A#2 B#303 G65 L03 P#405 A#404 B#305 G01 U#305 F2500 G01 U#405 V#403 F#165 G01 U#303 F2500 G65 L81 P80 A#307 B0 G65 L04 P#406 A#307 B360000 G65 L03 P#407 A#2 B#306 G65 L03 P#408 A#407 B#308 G01 U-#306 F2500 G01 U-#408 V#406 F#165 G01 U-#308 F2500 G65 L81 P80 A#310 B0 G65 L04 P#409 A#310 B360000 G65 L03 P#410 A#2 B#309 G65 L03 P#411 A#410 B#311 G01 U#311 F2500 G01 U#411 V#409 F#165 G01 U#309 F2500 G65 L81 P80 A#313 B0 G65 L04 P#412 A#313 B360000 G65 L03 P#413 A#2 B#312 G65 L03 P#414 A#413 B#314 G01 U-#312 F2500 G01 U-#414 V#412 F#165 G01 U-#314 F2500 G65 L81 P80 A#316 B0 G65 L04 P#415 A#316 B360000 G65 L03 P#416 A#2 B#315 G65 L03 P#417 A#416 B#317 G01 U#317 F2500 G01 U#417 V#415 F#165 G01 U#315 F2500 G65 L81 P80 A#319 B0 G65 L04 P#418 A#319 B360000 G65 L03 P#419 A#2 B#318 G65 L03 P#420 A#419 B#320 G01 U-#318 F2500 G01 U-#420 V#418 F#165 G01 U-#320 F2500 G65 L81 P80 A#322 B0 G65 L04 P#421 A#322 B360000 G65 L03 P#422 A#2 B#321 G65 L03 P#423 A#422 B#323 G01 U#323 F2500 G01 U#423 V#421 F#165 G01 U#321 F2500 G65 L81 P80 A#325 B0 G65 L04 P#424 A#325 B360000 G65 L03 P#425 A#2 B#324 G65 L03 P#426 A#425 B#326 G01 U-#324 F2500 G01 U-#426 V#424 F#165 G01 U-#326 F2500 G65 L81 P80 A#328 B0 G65 L04 P#427 A#328 B360000 G65 L03 P#428 A#2 B#327 G65 L03 P#429 A#428 B#329 G01 U#329 F2500 G01 U#429 V#427 F#165 G01 U#327 F2500 G65 L81 P80 A#331 B0 G65 L04 P#430 A#331 B360000 G65 L03 P#431 A#2 B#330 G65 L03 P#432 A#431 B#332 G01 U-#330 F2500 G01 U-#432 V#430 F#165 G01 U-#332 F2500 G65 L81 P80 A#334 B0 G65 L04 P#433 A#334 B360000 G65 L03 P#434 A#2 B#333 G65 L03 P#435 A#434 B#335 G01 U#335 F2500 G01 U#435 V#433 F#165 G01 U#333 F2500 N80 G01 X#5 Y0. F5000 G01 V#166 F10000 M112 G12 P98 G65 L02 P#160 A#160 B1 M99 5 Conclusion This CNC stator winding machine control scheme features high control precision, strong system stability, and flexible user operation. It serves as a typical case study of utilizing the Delta CNC system and Delta servo motors in the winding machine industry. Utilizing Delta Electronics' open, full-featured general-purpose CNC system, combined with the superior performance of Delta's servo systems, dedicated control systems can be flexibly integrated, providing more valuable integrated solutions to meet the specific requirements of different customers and industries. (Proceedings of the 2nd Servo and Motion Control Forum; Proceedings of the 3rd Servo and Motion Control Forum)