Winding Equipment for Small and Micro Motors ｜ ZHPWT

Due to their small size and precise structure, micro and miniature motors (such as brushless motors, stepper motors, and micro servo motors) have winding processes that differ significantly from those of traditional large motors, and they impose even more stringent requirements on the manufacturing process.

⚬ Extremely Fine Wire Diameter: The enameled wire used in micro and miniature motors typically ranges in diameter from 0.02 mm to 0.3 mm. This extremely fine wire has low physical strength and is highly susceptible to breakage or damage to its insulation during high-speed winding.

⚬ Strict Tension Control: Tension must be maintained at a highly stable level throughout the winding process. Excessive tension can easily cause wire breakage or elongation of the copper wire, altering resistance; insufficient tension, on the other hand, can result in a loose coil, affecting slot fill rate and motor power.

⚬ Compact spatial layout: The stator or rotor slots in micro motors are extremely narrow, requiring the wire to be laid out very tightly and neatly, without any crossing or tangling, to ensure the highest possible slot fill rate within the limited space.

⚬ High precision in the number of turns: The error in the number of turns must be strictly controlled (typically requiring zero error). Inconsistencies in the number of turns directly lead to imbalances in resistance and inductance across phases, thereby affecting the motor’s electromagnetic performance, operational smoothness, and generating noise.

⚬ Reliance on automation: Since human visual acuity and hand stability cannot meet the micrometer-level requirements for wire arrangement and mounting, the winding of micro-motors relies heavily on fully automated equipment to complete processes such as winding, wire arrangement, mounting, and wire trimming.

Precision Winding Machines for Small and Micro Motors

How to Choose the Right Winding Equipment ?

When evaluating and purchasing winding machines for micro and small motors, you should focus on the equipment’s control accuracy, mechanical stability, and production adaptability.

Dual-Station Synchronous Winding for Doubled Efficiency

With independent control and alternating operation across two stations, the system simultaneously clamps two sets of fixtures, enabling non-stop loading and unloading for continuous winding, which significantly improves production cycle time.

Fully Automatic Winding Process

Automatic wire-end attachment, automatic wire clamping, automatic wire cutting (scissor-type or pull-type optional), automatic wire arrangement (program-set), and automatic slot changing reduce manual intervention and ensure winding consistency.

Precision Tension Control System

Comes standard with an electronic tensioner; a servo tensioner is available as an option. Winding tension can be precisely set via programming; the system automatically stops and sounds an alarm upon enameled wire breakage to prevent scrap production.

Wide Range of Supported Wire Diameters

Supports enameled wire diameters from φ0.05 to 0.35 mm, covering the common specifications required for micro and small motors.

Data Interconnectivity and MES Integration Support

Equipped with Ethernet/RS485 communication interfaces, supporting data upload and production traceability; includes a reserved MES interface to facilitate digital upgrades of production lines.

Open IO Control, Flexible and Adjustable

The equipment’s IO points are open; cylinders, light curtains, wire break sensors, and other components can be customized, facilitating process debugging and equipment integration.

User-Friendly Operation Design

The wire clamping fixture can be manually opened for wire clamping once it has completed reset or is in the ready-to-feed state, facilitating manual loading/unloading and emergency handling.

About ZHPWT

Guangdong Zongheng Technology Co., Ltd. has dedicated 19 years to the R&D and intelligent manufacturing of precision winding machines for hollow coils, Alpha coils, voice coils, and similar components. Our equipment is widely utilized across various sectors, including smartphones, 3C electronics, new energy vehicles, home appliances, aerospace and defense, nuclear power, and marine engineering. For more details, Contact us: +86-186 2185 7689/Email:tech@zhpwt.com.