What are the contents of pre-service training for employees of the manual four-station internal winding machine for brushless motors?
Contents of Pre-service Training for Employees of the Manual Four-station Internal Winding Machine for Brushless Motors
I. Basic Understanding of the Equipment
1. Structure Explanation
Introduce in detail the overall architecture of the winding machine, including the layout of the four stations, the winding mechanism, the wire feeding device, the wire arranging mechanism and other main components' positions and functions. For example, the winding mechanism drives the winding shaft to rotate at a high speed through the motor to realize the winding action of the wire on the stator core. The wire arranging mechanism drives the wire arranger to move axially along the winding shaft through the cooperation of the screw rod and the nut, ensuring that the wires are evenly and tightly arranged on the core. The wire feeding device can be divided into two types: active wire feeding and passive wire feeding. Active wire feeding controls the wire feeding speed through the motor, which is suitable for thinner and easily tangled wires; passive wire feeding relies on the tension of the wire itself to feed the wire, which is often used for thicker wires.
Show the transmission system of the equipment and explain how the transmission components such as belts, chains and gears work together to transmit power to each actuating mechanism. For example, the output shaft of the motor is connected to the input shaft of the reduction gearbox through a belt. After being shifted by the reduction gearbox, the power is transmitted to the winding shaft through a chain to realize the winding action; while the power of the wire arranging mechanism is realized through gear transmission to ensure the accuracy of the wire arranging action.
2. Explanation of the Working Principle
Elaborate on the basic working principle of the winding machine, that is, through manual operation and control, the wire is wound on the motor stator core according to the predetermined number of turns and mode. The operator needs to set parameters such as the number of winding turns, the winding speed, and the wire arranging pitch on the control panel according to the motor specifications and the winding process requirements. The equipment control system controls the motor and the wire arranging mechanism to work together according to the set parameters to complete the winding task.
Explain the working mode of the four stations, illustrate how the four stations work independently or alternately to improve production efficiency, as well as the operation key points and precautions when switching stations. In the independent working mode, the four stations can simultaneously carry out the winding operations of products with different specifications; the alternate working mode is suitable for mass production of products with the same specification. When one station finishes the winding, it can quickly switch to another station to continue production, reducing the equipment waiting time. When switching stations, the operator should first press the stop button of the current station. After the equipment stops running completely, carefully take out the wound stator core, put in a new core, and adjust the relevant parameters according to the product requirements.
3. Explanation of Technical Parameters
Introduce the key technical parameters of the winding machine, such as the winding speed range, the maximum number of winding turns, the applicable wire specifications (wire diameter range), the motor power, etc. The winding speed is usually between 50 and 500 revolutions per minute, which can be adjusted according to the wire material and the thickness of the wire diameter; the maximum number of winding turns can generally reach several thousand turns, and the specific value depends on the equipment model and the performance of the control system; the applicable wire diameter range is 0.1 - 3 mm, covering the common specifications of motor winding wires; the motor power generally ranges from 0.5 to 3 kilowatts according to the size of the equipment and the winding load.
Let the employees understand the influence of different parameters on the winding quality and efficiency, as well as how to reasonably adjust these parameters according to the actual production requirements. For example, if the winding speed is too fast, it may cause the wires to be arranged irregularly and loosely, or even break; inaccurate number of winding turns will directly affect the performance of the motor; if the wire diameter exceeds the applicable range, it may not be possible to wind the wire normally or damage the equipment. In actual operation, if winding thinner wires, the winding speed should be appropriately reduced and the wire arranging accuracy should be improved; for winding tasks with a large number of turns, it is necessary to ensure the accuracy of parameter settings and closely observe the counter value during the winding process.
II. Training on Operation Specifications
1. Startup and Shutdown Procedures
Demonstrate the correct startup sequence, including connecting the power supply, starting the control system, and checking the initial state of the equipment. Emphasize that before starting up, check whether the appearance of the equipment is intact, whether the connections of all components are firm, and whether there are any foreign objects blocking. After connecting the power supply, wait for the control system to complete the self-check and observe whether the indicator lights on the control panel are normally displayed. If the indicator lights are abnormal, immediately troubleshoot the fault. Common faults include loose power lines and hardware failures of the controller. When checking the appearance of the equipment, focus on checking whether the moving parts of the winding mechanism and the wire arranging mechanism are stuck or deformed, and whether the wires are wound in a non-designated position.
Explain the shutdown procedure, first stop the winding operation, turn off the control system, and finally cut off the power supply. At the same time, remind the employees to conduct a simple cleaning and tidying of the equipment after shutdown. When stopping the winding operation, first press the stop button. After the winding shaft and the wire arranger stop moving completely, then turn off the control system. After shutdown, use a clean soft cloth to wipe the dust and oil stains on the surface of the equipment, clean up the sundries on the workbench, and check whether the wires are properly arranged to avoid potential hazards caused by scattered wires.
2. Manual Operation Steps
Winding Operation: Demonstrate step by step how to install the stator core onto the winding station, adjust the position and fix it; select the appropriate wire, and correctly place the wire end on the winding mold; start the winding motor and carry out the winding operation according to the set number of turns and speed. During the winding process, teach the employees how to observe the winding status, such as whether the wires are neatly arranged and whether there are any wire breakages, etc., and take corresponding measures in a timely manner. When installing the stator core, ensure that the center of the core is aligned with the center of the winding shaft, and use a special fixture to firmly fix the core to prevent the core from shifting during the winding process. When selecting the wire, confirm whether the wire material, wire diameter and insulation performance meet the standards according to the motor design requirements. When placing the wire end on the winding mold, ensure that the wire end is firmly fixed to avoid the wire end loosening at the beginning of the winding. During the winding process, if it is found that the wires are not neatly arranged, immediately suspend the winding, manually adjust the position of the wire arranger, and continue the winding after the wires are rearranged neatly; if there is a wire breakage, first find out the cause of the breakage, such as the wire quality problem or the excessive stretching of the wire caused by the too fast winding speed, etc. After replacing the new wire, reset the number of winding turns and continue the winding from the broken wire place.
Wire Arranging Operation: Introduce the operation method of the wire arranging mechanism, how to adjust the wire arranging knob or button to make the wire arranger arrange the wires according to the predetermined method and pitch, ensuring that the winding is even and tight without overlapping or skipping turns. The wire arranging knob or button generally has the functions of fine adjustment and coarse adjustment. The fine adjustment is used to precisely adjust the wire arranging pitch, and the coarse adjustment is used to quickly change the position of the wire arranger. Before winding, determine the appropriate wire arranging pitch through experiments according to the wire diameter and the number of winding layers. For example, for thinner wires and multi-layer winding, the wire arranging pitch should be appropriately reduced to ensure tight winding; for thicker wires, the wire arranging pitch can be appropriately increased to prevent the wires from being squeezed and deformed. During the winding process, always observe the wire arranging situation. If there are abnormal wire arranging situations, such as the wire arranger jumping or the wire arranging pitch being inconsistent, etc., immediately check whether there are foreign objects blocking the wire arranging mechanism and whether the transmission components are loose, and take corresponding measures.
Station Switching: Explain in detail the switching operation process between the four stations, including stopping the work of the current station, taking out the stator core from the current station and placing it in another station, adjusting the relevant parameters (such as the winding speed, the number of turns, etc., if there are differences for different products), and then starting the winding operation of the new station. Emphasize that care should be taken to prevent hand injuries when switching stations. When stopping the work of the current station, be sure to wait for the equipment to stop running completely, and avoid forcibly taking out the stator core during the operation of the equipment to avoid personal injury or equipment damage. When taking out the core, operate carefully to avoid colliding with other parts of the equipment. When placing the core in another station, also ensure that the installation position of the core is accurate and fixed firmly. When adjusting the parameters, carefully check the requirements of the new product to ensure that the parameter settings are correct. Before starting the winding operation of the new station, check the equipment status again, such as whether the wire is installed correctly and whether the position of the wire arranger is appropriate, etc.
3. Parameter Setting Method
Guide the employees on how to set the winding parameters, such as the winding speed, the number of turns, the wire arranging pitch, etc., on the equipment control panel. Explain the meaning and setting range of each parameter, as well as how to make reasonable settings according to different motor models, wire specifications and winding process requirements. When setting the winding speed, the wire material and wire diameter need to be considered. For example, for copper wires, when the wire diameter is thinner, the winding speed can be appropriately increased, but it should not exceed the maximum speed allowed by the equipment; for aluminum wires, because of their soft texture, the winding speed should be relatively reduced to avoid wire deformation. The setting of the number of winding turns should be in strict accordance with the motor design requirements, and the number of turns should be accurately input. At the same time, pay attention to setting the tolerance range of the number of turns, generally, the tolerance range can be controlled within ±1 - 2 turns. The setting of the wire arranging pitch needs to be determined according to the wire diameter and the number of winding layers. The thinner the wire diameter and the more the number of layers, the smaller the wire arranging pitch.
Through practical cases, let the employees practice parameter setting, and check whether the setting results are correct to ensure that they can master the parameter setting skills proficiently. For example, given a motor model, knowing its stator core specifications, wire diameter and the requirements for the number of winding turns, let the employees carry out parameter setting on the equipment. After completing the setting, check whether the parameters are consistent with the requirements. At the same time, simulate the winding process and observe whether the wire arranging effect and the winding speed are reasonable. If the parameter setting is unreasonable, such as the wire arranging is not neat due to the too fast winding speed, guide the employees to analyze the reasons and readjust the parameters until the ideal winding effect is achieved.
III. Key Points of Quality Control
1. Explanation of Winding Quality Standards
Clarify various standards of winding quality, such as the accuracy of the number of winding turns (allowable error range), the neatness of wire arrangement (whether it is tight, without overlapping or skipping turns), the tightness of winding (it should not be too loose to cause the coil to be loose, nor too tight to damage the insulation layer of the wire), etc. The allowable error range of the number of winding turns is generally ±1 - 2 turns. Exceeding this range may affect the performance parameters of the motor, such as torque and speed. The wires should be arranged tightly and neatly. There should be no obvious gaps or overlaps between adjacent wires, and there should be no skipping turns, otherwise it will lead to uneven magnetic fields of the motor and reduce the motor efficiency. The tightness of the winding should be moderate. Too loose winding will make the coil shake on the core, affecting the stability of the motor; too tight winding may damage the insulation layer of the wire and cause a short-circuit fault.
Show samples of qualified and unqualified products, so that employees can intuitively understand the specific requirements of the quality standards, as well as the possible defect types and reasons of unqualified products. By comparing the winding appearances of qualified and unqualified products, for example, for products with inaccurate number of turns, the number of turns displayed by the counter does not match the actual number of winding turns; for products with unneat wire arrangement, obvious wire overlapping or excessive gaps can be seen; for products with too loose winding, the coil has signs of looseness on the core; for products with too tight winding, the insulation layer of the wire may be damaged. Analyze the reasons for these defects, such as incorrect parameter setting, unskilled operation, equipment failure, etc., so that employees can deeply understand the importance of quality standards.
2. Methods of Process Quality Inspection
Train employees on how to conduct quality inspection during the winding process, such as using a counter to check whether the number of winding turns reaches the set value; observing with the naked eye whether the wires are neatly arranged, and whether there are wire breakages, knotting, etc.; touching the winding part by hand to feel whether the tightness of the winding is appropriate. The counter is generally installed on the equipment control panel and displays the number of winding turns in real time. During the winding process, employees should regularly observe the counter value. When approaching the set number of turns, pay close attention to the winding situation to ensure the accuracy of the number of turns. When observing with the naked eye, focus on checking the arrangement of the wires on the winding mold, and check turn by turn from the starting end to the end of the winding whether there are wire breakages, knotting, overlapping or skipping turns. When touching the winding part by hand, gently press the coil to feel its tightness. If the coil feels too loose or too tight, it is necessary to adjust the winding parameters or the operation method in a timely manner.
Teach employees how to use simple measuring tools, such as a caliper to measure the outer diameter or width of the winding to determine whether the winding meets the process requirements. According to the motor design drawings, determine the standard value of the outer diameter or width after the winding is completed. When using a caliper to measure, make the measuring jaws of the caliper perpendicular to the winding direction, gently clamp the winding part, and read the value of the caliper. If the measured value deviates greatly from the standard value, it may be caused by reasons such as inaccurate number of winding turns, unneat wire arrangement or inappropriate tightness of the winding, etc., and it is necessary to further investigate the problem and make adjustments.
3. Measures for Handling Quality Problems
Analyze the causes of common winding quality problems, such as insufficient number of turns, unneat wire arrangement, wire breakage, etc., such as incorrect parameter setting, improper operation, equipment failure, etc. Insufficient number of turns may be caused by reasons such as counter failure, incorrect parameter setting or sudden stop of the equipment during the winding process; unneat wire arrangement may be caused by reasons such as wire arranging mechanism failure, unreasonable parameter setting or the operator not adjusting the position of the wire arranger in time; wire breakage may be caused by factors such as wire quality problems, too fast winding speed, too large winding tension, etc.
For different quality problems, explain the corresponding handling measures, such as if insufficient number of turns is found, adjust the winding parameters in time and rewind the wire; for unneat wire arrangement, the winding can be suspended, the position of the wire arranger can be adjusted manually, and then the winding can be continued; if the wire breaks, it is necessary to find out the cause of the breakage (such as wire quality problems, excessive pulling during the winding process, etc.), replace the wire, and then start winding again. If insufficient number of turns is found, first check whether the counter is working normally. If the counter fails, repair or replace it in time; if the parameter setting is wrong, recheck and input the correct number of turns value, and then start the winding operation to make up for the number of turns. For the situation of unneat wire arrangement, after suspending the winding, check whether there are foreign objects blocking the wire arranging mechanism. If so, clean up the foreign objects; at the same time, check whether the wire arranging parameter setting is reasonable, and adjust it if necessary, and then manually adjust the wire arranger to the correct position and continue the winding. If the wire breaks, first check the wire quality, such as whether there are obvious defects, embrittlement and other phenomena of the wire. If there are wire quality problems, replace the qualified wire; if it is suspected that it is a problem of winding speed or tension, appropriately reduce the winding speed or adjust the tension device, and then start winding again.
IV. Training on Protection Knowledge
1. Identification of Equipment Risks
Point out the risks existing during the operation of the winding machine, such as the mechanical injuries that may be caused by the moving parts (motor, belt, gear, etc.), the electric shock hazards that may be caused by the electrical system, and the personal injuries that may be caused by improper operation (such as touching the running parts with hands, excessive force causing damage to the parts, etc.) during the operation process. When the moving parts are running at a high speed, if the operator's hand accidentally touches them, it may be involved and cause serious mechanical injuries. If the electrical system is poorly grounded or the wires are damaged, the operator may have an electric shock accident when touching the equipment. Improper operations such as forcibly adjusting the position of the parts when the equipment is running and forcefully pulling the control buttons may not only damage the equipment, but also cause personal injuries due to the sudden out-of-control of the equipment.
Through pictures, videos or actual cases, let the employees intuitively understand the harm degree of these risks and improve their awareness. Show some pictures or videos of personnel injuries caused by equipment accidents, such as fractures caused by fingers being involved in the belt and burns caused by electric shock accidents, so that employees can deeply understand the seriousness of the accidents. At the same time, share some actual cases of equipment failures caused by improper operations, such as the operator touching the winding shaft during the winding process, resulting in hand injuries and equipment damage due to collisions, so that employees can understand the importance of following the operation procedures.
2. Emphasis on Operating Procedures
Emphasize that the operating procedures of the equipment must be strictly observed, such as it is prohibited to put hands into the area of moving parts when the equipment is running; ensure that the equipment is well grounded before operation to prevent electric shock accidents; do not arbitrarily change the electrical lines or parameters of the equipment to avoid causing equipment failures or
