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Electric motors are becoming increasingly ubiquitous. Demand from emerging applications, such as EVs, is exploding. Market value will grow to $186 billion by 2027, up from $134 billion today, according to some predictions.
Making all those motors, though, requires brushless DC electric motor (BLDC) winding machines. But what are they, exactly?
You’re about to find out. This article discusses what BLDC winding machines are for, a brief overview of their structure, the types of motor winding machines available, and some industries that commonly use BLDC motor winding machines.
As the name suggests, a BLDC motor winding machine is a piece of equipment that wraps the coils of brushless DC motors, a type of electric motor that doesn’t use brushes praised for its reliability. Machines use spools, wire cutters, automatic loading and unloading, and mechanical arms to deliver coils to battery rotors or stators in a proven configuration to establish a reliable rotating magnetic field.
Aerospace firms that require motors for wing flaps and onboard mechanical operations, such as lowering and raising landing gear on aircraft
Automotive firms requiring motors for electric vehicles and hybrid electric vehicles
Consumer appliance manufacturers for use in dishwashers, washing machines, and dryers
The advantages of BLDC motor winding machines are considerable. The primary benefit is automation: electric motor manufacturers can reduce the labor required to wind coils in electric motors.
BLDC machines are also more precise. Devices wrap coils to predictable tolerances, ensuring they remain within specification.
Finally, BLDC winding machines enable higher volume production. Manufacturers can produce vast quantities of motors they require for various applications.
An Overview of the Important Structures and Components of a BLDC Motor Winding Machine.
BLDC motor winding machines contain several components that let them carry out their function. The frame is the outer chassis supporting the entire device. Almost always made of rigid metal, it ensures stability during operation.
The stator winding station is a device that wraps wire coils onto the fixed part of the motor, called the stator. It typically includes several sub-components, including a spool holder for the wire, a tensioning mechanism to ensure proper deposition and a high-performance winding head.
The rotor winding station is responsible for winding coils onto the moving part of the motor. It connects to the wire dispensing system: a collection of spool holders, tension control mechanisms, and wire guides that allow continuous coil application to motor units. Wire cutters and terminators cut the wire once the machine delivers the desired number of coils to the motor.
Many units also come with additional extras to make them more efficient or suitable for intensive production applications. For instance, some models have control panels allowing technicians to set parameters controlling the speed and tension of winding. Many also have emergency safety features, such as stop buttons and wire guards, to keep workers safe. Software control is also an option on some machines, letting manufacturers switch between winding patterns and wire configurations.
While BLDC winding machines contain similar components, their rotor configurations differ depending on the motor type they produce.
Inner Rotor BLDC Winding Machines
Inner rotor BLDC winding machines place the rotor inside the stator. Machines then wind the wire around the inner rotors.
Outer Rotor BLDC Winding Machines
Outer rotor BLDC winding machines wind coil around a rotor outside the stator. Most of these machines have rotary components that help wind coils around the outer structure at high speed.
Axial Flux BLDC Motor Winding Machine
Axial flux BLDC motor winding machines create motors where the axis of rotation is parallel to the direction of magnetic flux. These motors need a special type of winding process that uses a linear motion.
Radial Flux BLDC Motor Winding Machine
A radial flux BLDC winding machine creates motors where the magnetic flux of the resulting motor emanates from the center of the device to the outer edges. These require winding machines that wrap coils of fractional-slot concentrated windings around motor teeth to avoid overlapping.
How Rotor BLDC Motor Winding Machine
Another variation is the hollow rotor BLDC motor winding machine. These machines wind coils to fit inside hollow-style motors. Many designs simply pre-wind the wire for later insertion into the motor body.
Introduction to the Operating Principle of a BLDC Motor Winding Machine
The essence of BLDC motor winding machines involves automating the somewhat challenging process of winding a series of metal coils onto a brushless electric motor’s stator or rotor. The goal is to streamline manufacturing and reduce labor in construction. Winding machines must operate efficiently and consistently to meet manufacturer specifications.
Step 1: Setting Up
The motor winding process begins with a technician setting up or calibrating the machine using software or an interface panel. This individual punches in the required parameters, such as the number of windings, winding program, and speed.
Step 2: Winding
The next step is to wind the wire. Most machines do this from a spool, using a series of rollers to straighten and direct the metal’s movement. Machines also have tensioning devices built in. These prevent the wire from moving away from the target rotor or stator and keep coils uniform and straight, ensuring a non-lumpy magnetic field on the finished motor.
Step 3: The Winding Head Moves
The final step is the movement of the winding head. The shape and speed of this head differ depending on the brushless DC motor’s rotor type. Usually, the head is a robust arm that guides the wire into the correct position, using a pre-calibrated motion.
Explore our products today and get faster, more efficient, and affordable coil winding systems for your motors. For inquiries about Parallel Winding Machine, Stator Winding Machine, Winding Machine Accessories or price list, please leave your email to us and we will be in touch within 24 hours.
