What are the contents of the pre-job training for employees operating the brushless motor manual dual-station internal winding machine?

First, the basic knowledge of the equipment

1、Structure explanation

Detailed introduction to the overall structure of the winding machine, including the layout of the duplex station, winding mechanism, wire release device, wire arrangement mechanism and other major components of the location and function. For example, the winding mechanism drives the winding shaft to rotate at 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 along the axial direction of the winding shaft through the cooperation of the screw and nut to ensure that the wires are evenly and closely arranged on the iron core. Release device can be divided into active release and passive release two types, active release through the motor to control the release speed, suitable for finer and easy to wind the wire; passive release rely on the wire's own tension release, commonly used in thicker wires.

Show the transmission system of the equipment, explain how belts, chains, gears and other transmission components work together to transfer power to the various actuators. For example, the motor output shaft is connected to the input shaft of the gearbox through the belt, and after the speed change of the gearbox, the power will be transmitted to the winding shaft through the chain to realize the winding action; and the power of the wire discharge mechanism is realized through the gear drive to ensure the accuracy of the wire discharge action.

2、Working Principle Explanation

Explain the basic working principle of the winding machine, that is, through manual operation and control, the wire will be wound on the stator core of the motor in accordance with the predetermined number of turns and the way. According to the motor specifications and winding process requirements, the operator needs to set the number of winding turns, winding speed, row spacing and other parameters on the control panel. The control system of the equipment controls the motor and the wire arranging mechanism to work together to complete the winding task according to the set parameters.

Explain the working mode of the dual-station, explain how the two stations work independently or alternately to improve production efficiency, as well as the operating points and precautions when switching stations. In independent working mode, the two stations can simultaneously carry out winding operations for products of different specifications; alternate working mode is suitable for mass production of products of the same specification, and when one station finishes winding, it quickly switches to the other station to continue production, reducing the waiting time for the equipment. When switching working stations, the operator should first press the stop button of the current working station, wait for the equipment to stop running completely, then carefully take out the wound stator core and put in the new core, and adjust the relevant parameters according to the requirements of the products.

3、Description of technical parameters

Introduce the key technical parameters of the winding machine, such as the range of winding speed, great winding turns, applicable wire specifications (wire diameter range), motor power and so on. The winding speed is usually between 50 - 500 revolutions per minute, which can be adjusted according to the material of the wire and the thickness of the wire diameter; the maximum number of turns can be up to several thousands of turns, depending on the model of the equipment and the performance of the control system; the range of applicable wire diameters is from 0.1 - 3 mm, which covers the common specifications of the motor winding wires; the power of the motor varies according to the size of the equipment and the winding load, which is usually between 0.5 - 3 kilowatts. The power of the motor varies from 0.5 to 3 kilowatts depending on the equipment size and winding load.

Employees will understand the impact of different parameters on the quality and efficiency of winding, and how to rationally adjust these parameters according to the actual production needs. For example, too fast winding speed may lead to untidy and loose wire arrangement or even broken wire; inaccurate number of winding turns will directly affect the motor performance; wire diameter beyond the applicable range may not be able to wind properly or damage the equipment. In actual operation, if winding finer wires, the winding speed should be appropriately reduced to improve the accuracy of the arrangement; for winding tasks with more turns, it is necessary to ensure that the parameters are set accurately and the counter value is closely observed during the winding process.

Second, the operation specification training

1、Power on and power off process

Demonstrate the correct sequence of power-on, including the steps of turning on the power, starting the control system and checking the initial state of the equipment. Emphasize the need to check whether the appearance of the equipment is intact, whether the parts are firmly connected, and whether there are any foreign objects blocking the equipment before powering on. After turning on the power, wait for the control system to complete the self-test, and observe whether the indicator lights on the control panel display normally. If the indicator light is abnormal, you should immediately troubleshooting, common faults include loose power lines, controller hardware failure. When checking the appearance of the equipment, focus on checking whether the moving parts of the winding mechanism and the wire arrangement mechanism are stuck and deformed, and whether the wires are wound in a non-specified position.

Explain the process of shutting down the machine, first stop the winding operation, turn off the control system, and cut off the power supply at the back. At the same time, remind employees to simply clean and organize the equipment after shutting down the machine. When stopping the winding operation, press the stop button first, and then turn off the control system after the winding spool and arranger completely stop moving. After shutting down the machine, use a clean soft cloth to wipe the dust and oil on the surface of the equipment, clean up the sundries on the workbench, and check whether the wires are properly organized to avoid hidden dangers caused by the scattering of wires.

2、Manual operation steps

Winding operation: Demonstrate step by step how to install the stator core into the winding station, adjust the position and fix it; choose the right wire and place the wire head on the winding mold correctly; 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, whether there is any broken wire, etc., and take corresponding measures in time. When installing the stator core, make sure that the center of the core is aligned with the center of the winding axis, and use a special fixture to fix the core firmly to prevent the core from being displaced during the winding process. When selecting wires, according to the design requirements of the motor, make sure that the wire material, wire diameter and insulation performance are in accordance with the standard. When placing the wire head on the winding mold, make sure that the wire head is firmly fixed to avoid the wire head loosening at the beginning of the winding process. During the winding process, if you find that the wires are not neatly arranged, you should immediately pause the winding, manually adjust the position of the wire arranger, so that the wires can be rearranged neatly and then continue to wind; if there is a broken wire, you need to find out the reason for the breakage of the wire, such as wire quality, excessive stretching of the wire due to excessive speed, etc., and then replace it with a new one, reset the number of winding turns, and then continue to wind from the point where the wire is broken.

Arranging operation: Introduces the operation method of the arranging mechanism, how to adjust the arranging knob or button, so that the arranging device in accordance with the predetermined way and spacing for arranging, to ensure that the winding is uniform, close, without overlapping or jumping turns phenomenon. The spooler knob or button generally has a fine adjustment and coarse adjustment function, the fine adjustment is used to adjust the spacing of the spooler accurately, while the coarse adjustment is used to change the position of the spooler quickly. Before winding, according to the wire diameter and the number of winding layers, the appropriate spacing is determined by test. For example, for thinner wires and multi-layer winding, the spacing between the wires should be adjusted appropriately to ensure that the winding is tight; for thicker wires, the spacing between the wires can be adjusted appropriately to prevent the wire from extruding and deforming. In the winding process, we should always observe the row of wires, if you find abnormal row of wires, such as row of wires jumping, row of wires spacing inconsistency, etc., you should promptly check the row of wires whether the mechanism of foreign objects blocking, whether the transmission components are loose, and deal with it accordingly.

Workstation switching: Detailed description of the switching process between the two workstations, including stopping the current workstation, the stator core from the current workstation and placed in another workstation, adjusting the relevant parameters (such as winding speed, number of turns, etc., if there are differences in the different products) to start the winding operation of the new workstation. Emphasize the importance of preventing hand injuries when switching stations. When stopping the work of the current station, be sure to wait until the equipment stops running completely to avoid forcibly removing the stator core during the operation of the equipment, which may cause personal injury or equipment damage. When removing the iron core, be careful to avoid collision with other parts of the equipment. When placing the iron core to another work station, also make sure that the iron core is installed in an accurate position and fixed firmly. When adjusting the parameters, carefully check the new product requirements to ensure that the parameters are set correctly. Before starting the new station winding operation, check the status of the equipment again, such as whether the wire is installed correctly, whether the position of the wire arranger is appropriate.

3、Parameter setting method

Instruct employees how to set the winding parameters on the control panel of the equipment, such as winding speed, number of turns, row spacing and so on. Explain the meaning and setting range of each parameter, and how to make reasonable settings according to different motor models, wire specifications and winding process requirements. Winding speed settings, need to take into account the material and wire diameter, for example, for copper wire, wire diameter is thin, the winding speed can be increased, but should not exceed the maximum speed allowed by the equipment; for aluminum wire, because of its softer texture, the winding speed should be relatively low, so as to avoid deformation of the wire. Winding turns set in strict accordance with the motor design requirements, accurate input turns value, while paying attention to set the turns of the tolerance range, the general tolerance range can be controlled in ± 1 - 2 turns. Line spacing settings should be determined according to the wire diameter and the number of winding layers, the finer the wire diameter, the more layers, the smaller the line spacing.

Through actual cases, let employees practice parameter setting and check whether the setting result is correct to ensure that they can master the parameter setting skills. For example, given a motor model with known stator core specifications, wire diameter and number of winding turns required, have employees perform parameter settings on the equipment. After completing the setup, check whether the parameters are consistent with the requirements, while simulating the winding process, observe the line effect and winding speed is reasonable. If the parameter setting is not reasonable, such as winding speed is too fast resulting in rows of wire is not neat, guide employees to analyze the reasons, re-adjust the parameters, until the ideal winding effect.

Third, quality control points

1、Winding quality standard explanation

Clearly define the quality standards of winding, such as the accuracy of the number of turns of winding (allowable error range), the neatness of the wire arrangement (whether it is tight, there is no overlap or jumping turns), the tightness of the winding (can not be too loose resulting in loose coils, and can not be too tight resulting in damage to the insulation layer of the wire), and so on. The allowable error range of winding turns is generally ±1 - 2 turns, beyond which the performance parameters of the motor, such as torque, speed, etc., may be affected. Wire arrangement should be tight and neat, there can be no obvious gap or overlap between adjacent wires, not to mention the phenomenon of jumping turns, otherwise it will lead to uneven magnetic field of the motor, reducing the efficiency of the motor. The tightness of the winding should be moderate, too loose winding will make the coil shake on the iron core, affecting the stability of the motor; too tight winding may damage the wire insulation layer, triggering short-circuit failure.

Displaying samples of qualified and unqualified products allows employees to visualize the specific requirements of quality standards, as well as the types of defects and causes that may occur in unqualified products. By comparing the winding appearance of qualified and unqualified products, such as inaccurate number of turns, the number of turns shown on the counter does not match the actual number of turns of the winding; wire arrangement is not neatly arranged products, visible overlap of the wire or gap is too large; winding is too loose products, there are signs of loosening of coils in the core; winding is too tight products, the wire insulation layer may be damaged. Analyze the reasons for these defects, such as parameter setting errors, unskilled operation, equipment failure, etc., so that employees deeply understand the importance of quality standards.

2、Process quality inspection methods

Train employees in the winding process how to carry out quality inspection, such as the use of counters to check whether the number of turns of winding reaches the set value; through the naked eye to observe whether the wires are neatly arranged, there are no broken wires, knots, etc.; touch the part of the winding, feel the tightness of the winding is appropriate. The counter is usually installed on the control panel of the equipment, which shows the number of winding turns in real time. Employees in the winding process, to regularly observe the counter value, when close to the set number of turns, pay close attention to the winding situation to ensure that the number of turns is accurate. When observing with the naked eye, focus on the arrangement of the wire on the winding mold, from the beginning to the end of the winding, checking turn by turn whether there are broken wires, knots, overlapping or jumping turns. When touching the winding part by hand, gently press the coil to feel its looseness or tightness. If the coil feels too loose or too tight, the winding parameters or operation methods need to be adjusted in time.

Teach employees how to use simple measuring instruments, such as calipers to measure the outer diameter or width of the winding wire, in order to determine whether the winding wire meets the process requirements. Determine the standard value of the outside diameter or width of the completed winding according to the motor design drawings. When using calipers to measure, the measuring claw of the caliper is perpendicular to the direction of the winding, gently stuck on the winding part, and read the value of the caliper. If the measured value and the standard value deviation is too large, may be inaccurate winding turns, wire alignment is not neat or winding tension is not appropriate and other reasons, need to further investigate the problem and make adjustments.

3. Emergency response

Formulate response plans for common emergencies, such as sudden equipment failures, fires, and injuries. Train employees in emergency situations how to operate correctly, such as immediately press the emergency stop button to stop the operation of the equipment; the use of fire extinguishers for the early stages of fire fighting (if the employees have been trained and have the ability to extinguish fires); call the emergency personnel in a timely manner and the injured person to carry out simple first aid treatment (such as stopping the bleeding, bandaging, etc., provided that employees master the basic knowledge of first aid). When the equipment suddenly fails, the operator should press the emergency stop button in time to prevent further expansion of the fault. If the failure leads to equipment smoke, fire, the scene if there is a fire extinguisher after the use of fire extinguisher training and have the ability to extinguish the fire employees, should quickly take the fire extinguisher, according to “a mention, two pull, three grip, four pressure” method of operation, aimed at the root of the fire source to extinguish the fire. In the event of injury, immediately call the first aid personnel (e.g., call 120 first aid phone), at the same time, if the staff masters the basic knowledge of first aid, the injured person can be simple bleeding, bandage treatment, such as the use of clean gauze or towels to stop the bleeding of wounds, bandage fixation to prevent infection and deterioration of the wound.

Regularly organize emergency drills so that employees are familiar with the response process and improve their ability to deal with emergencies in an emergency. Regularly organize drills for emergencies such as equipment failures, fires, and injuries, simulating real scenarios, so that employees can actually operate emergency equipment such as emergency stop buttons and fire extinguishers, and practice first-aid treatment during the drills. After the end of the drill, the drill process is summarized and evaluated, and targeted training and improvement is carried out for the problems arising from the drill, such as unskilled operation of employees, slow emergency response, etc., so as to continuously improve the emergency handling ability of employees.

V. General knowledge of equipment maintenance

Daily maintenance points

Explain the importance of daily maintenance of equipment and specific content, including the end of each day's work on the equipment to clean, clear off the surface of the equipment, dust, oil and debris, to prevent it from entering the equipment to affect the normal operation of the internal. Dust, oil and debris on the surface of the equipment, if not cleaned in time, may enter the equipment through the equipment's cooling holes, gaps, etc., attached to the electrical components, mechanical components, affecting the thermal performance of the equipment, accelerating the wear and tear of the components, and even lead to electrical short circuits and other faults. At the end of each day's work, use a clean soft cloth or compressed air gun to carefully clean the dust and debris on the surface of the equipment, the winding mechanism, the wire arrangement mechanism, the wire release device and other parts. For oil stains, special cleaners can be used to wipe, but be careful that the cleaners do not corrode the surface of the equipment.

※ If you need help, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool for assistance.