What are the key maintenance measures for stator winding machines?

If you are in the motor manufacturing industry, you must know that stator winding machines are crucial in your production line. Whether you are producing motors for electric vehicles, household appliances or industrial equipment, keeping winding machines in optimal condition ensures consistent quality, higher efficiency and minimal downtime.

So how do you properly maintain stator winding machines? Here are some key measures to help you ensure that your equipment runs smoothly day after day.

1. Regular cleaning

It sounds simple, but dust and wire shavings can be serious health hazards. Over time, particles from insulation or trimmed wires can accumulate around winding heads, sensors and moving parts. If left untreated, these accumulations can affect sensor readings and even cause mechanical failure.

Tips:

After each shift, use compressed air to blow away dust and deep clean the machine once a week.

2. Check and lubricate moving parts

Winding heads, bearings, slides and guides are all in constant motion. Without proper lubrication, friction increases, causing premature wear of parts.

Tip:

Follow the manufacturer's lubrication schedule and always use the recommended lubricant. Don't overdo it—excess oil attracts dust.

3. Check the wire guides and nozzles

These little parts make a big difference. If they're worn or misaligned, you might see inconsistent coil tension or broken wire, both of which can affect an entire batch.

Tip:

Visually inspect the wire guides daily for wear or buildup. Replace them if they're noticeably deformed or the wire feed is erratic.

4. Monitor electrical and control systems

Modern winding machines rely heavily on PLC systems, servos, and sensors. If any of these systems are out of sync, the winding process can easily produce scrap or stall.

Tip:

Perform monthly diagnostics and back up the machine's control software regularly. Keep an eye on warning messages on the human-machine interface (HMI) and don't ignore them!

5. Tension control calibration

Wire tension is key to winding quality. If the tensioner isn't working properly, you might see problems like uneven winding or damaged insulation.

Tip:

Use a tension gauge to check calibration regularly. The tensioner should be cleaned and adjusted based on the type and size of wire being used.

6. Check for mechanical play or looseness

Loose bolts, misaligned parts, or unusual vibrations often indicate a problem. These minor issues can lead to long-term accuracy issues.

Tip:

During weekly inspections, gently shake components such as the coil former, winding nozzle, and winding arm. If you notice any unexpected play, stop operation and inspect before continuing.

7. Schedule preventive maintenance

Don’t wait until problems arise. A well-developed preventive maintenance program can help you prevent failures before they occur and maximize your machine’s uptime.

Tip:

Create a maintenance checklist and log. Include intervals for changing belts, tightening fixtures, checking drive systems, and updating firmware (if applicable).

8. Train operators and maintenance personnel

Even the best maintenance plan will be useless if your team doesn’t understand how to use the machine properly. Operator error is a common cause of machine failure.

Tips:

Regular training helps operators spot early warning signs and perform routine maintenance on their own.

Conclusion

Maintaining your stator winding machine is not just about extending its life, but also about ensuring production quality and minimizing downtime. Just a few minutes a day and some regular deep maintenance every month can save hours of lost production and expensive repairs.

Invest the time in maintenance and your winding machine will reward you with stable and reliable performance.

Zongheng is a manufacturer of the Stator/Rotor Winding Machine. Our motor stator winding machine products are produced efficiently and stably. With personalized customization, we provide highly automated, information-based, flexible comprehensive solutions for new energy vehicle motors, auto parts and other automation equipment.Visit our website at www.zhpwt.com to learn more about our products. For inquiries, you can reach us at tech(at)zhpwt.com.