Axial Flux Motor Coil - Project Details

As electric drive systems evolve toward greater lightweighting and higher power density, the application of axial flux motors is becoming increasingly widespread. As a manufacturer of precision winding equipment, we are dedicated to overcoming the core process challenges inherent in the manufacturing of axial flux stators.

Compact Wire Laying Process: 

Our equipment enables the compact arrangement of copper wire within confined spaces, effectively boosting the slot fill factor and helping motors achieve superior magnetic flux efficiency and thermal dissipation performance.

Stable Tension Control: 

By employing a proprietary servo-driven tension control system, we ensure precise turn counts and uniform tension distribution during the winding process, thereby meeting the rigorous standards required for the modular assembly of axial flux motors.

Versatile Applicability: 

Our winding solutions are adaptable to conductors of various specifications—from miniature servo motors to industrial-grade drive modules—providing reliable manufacturing support across a wide spectrum of applications.

1. The Ultimate Pursuit of Space Utilization

The primary advantages of axial flux motors lie in their compact size and high torque output; consequently, they impose extremely stringent requirements on the coil's "fill factor."

• Key Considerations: It is imperative to ensure that the copper wire is arranged with extreme compactness within the sector-shaped coil former, strictly avoiding any crossovers.

• Process Requirements: This necessitates the use of precision wire-laying algorithms—particularly within the narrower inner-ring sections of the sector—where even a minute deviation in wire positioning can lead to stacking irregularities, thereby compromising the subsequent assembly of the motor modules.

2. Precise Tension Control

Axial motor coils typically feature a relatively flat profile; thus, any fluctuation in winding tension can result in wire deformation or damage to the insulation layer.

• Key Considerations: Constant tension must be maintained throughout the winding process. Excessive tension can cause the wire to stretch and thin out, thereby increasing electrical resistance; conversely, insufficient tension results in a loose coil structure, which can lead to electromagnetic vibration.

• Equipment Essentials: We recommend utilizing a full servo-driven, closed-loop tension control system capable of providing real-time compensation for tension fluctuations caused by variations in winding speed.

3. Geometric Precision of Coil Shape

Axial flux stators are typically constructed by assembling multiple individual modules (as illustrated in your accompanying image).

• Key Considerations: The external dimensions and geometric profile of each coil—specifically its height, width, and curvature—must exhibit a high degree of consistency and uniformity. If the coil is wound too thickly, it will prevent proper closure or result in gaps when the full circular assembly is joined.

• Process Requirements: Upon completion of the winding process, it is typically necessary to apply a precise shaping process—or utilize temperature-assisted shaping—to ensure that the geometric dimensional tolerances of the module are controlled within the micron range.

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.