Series excitation motor motor stator winding machine what are the common mechanical faults and solutions?
1, uneven winding tension fault
Failure phenomenon
Loose or too tight winding: During the winding process, the tension of the wire is unstable, which may lead to slack wire in part of the winding, making the winding not tight; or the wire is too tight, which may damage the insulation layer of the wire, or even pull off the wire.
Irregular coil shape: Due to uneven tension, the shape of the wound coil does not meet the requirements, and there may be localized bulging, depression, etc., which affects the performance of the motor.
Solution
Tension adjusting device check: Check the tension adjusting mechanism of the winding machine, such as tension spring, tension wheel and other components. If the tension spring is fatigued or damaged, it should be replaced with a new one. For the tension wheel, check whether it rotates flexibly and whether there is any wear on the surface, if there is any wear, it needs to be repaired or replaced.
Tension sensor calibration (if available): Some advanced winding machines are equipped with tension sensors to precisely control the winding tension. If the tension sensor deviation, you need to calibrate it, according to the steps of the equipment manual, use standard weights and other tools to calibrate the tension sensor to ensure that it can accurately measure and feedback tension information.
2、Row line mechanism failure
Failure phenomenon
Uneven row of wires: The wires cannot be neatly arranged in the stator slot or on the winding mold when winding, and there are phenomena such as different widths of rows of wires, overlapping or crossing, and so on.
Uneven wire arrangement: There is a jam in the process of arranging the wires, resulting in discontinuous arrangement of the wires, which may affect the speed and quality of the winding.
Solution
Check the gears and screws: The wire arranging mechanism usually consists of gears and screws to drive the movement of the arranger. Check these components for wear, damaged teeth, or bent screws. If you find worn gears, replace them with new ones; for a bent screw, try straightening or replacing the screw.
Clean and lubricate the row of wire tracks: the row of wires slides on the track, the track of dust, oil and other impurities may affect the smooth movement of the row of wires. Regularly clean the track, remove impurities, and apply the appropriate amount of lubricant to ensure that the wire rower can slide flexibly on the track.
3, winding mold damage failure
Failure phenomenon
Mold deformation: the winding mold may be deformed after long-term use or impact by external forces, resulting in the winding coil size does not meet the requirements and does not match with the stator core.
Wear and tear of the mold: The wear and tear of the surface of the mold will affect the winding quality of the coil, which may cause the coil to appear burrs, damage, and so on.
Solution
Die inspection and repair: Regularly check the shape and size of the winding die, for slight deformation of the die, you can try to use professional tools for shaping and repair. If the wear and tear is serious, the mold should be replaced with a new one, and when installing the new mold, make sure the installation position is accurate and firmly fixed.
Mold protection: In the process of use, avoid the mold to be collided and excessive pressure. You can set up guards around the mold to prevent other objects from accidentally hitting the mold.
4、Transmission parts failure
Failure phenomenon
Unstable transmission between motor and winding shaft: If the transmission is done through belt, chain or coupling, there may be slipping and skipping, resulting in unstable winding speed.
Noise caused by wear and tear of transmission parts: with the wear and tear of transmission parts, abnormal noise will be generated during operation, affecting the working environment and equipment life.
Solution
Inspection and adjustment of transmission parts: For belt transmission, check the tension of the belt, if the belt is too loose, the phenomenon of slipping will occur, and the tension of the belt can be increased by adjusting the belt tensioning wheel. For chain drive, check whether the chain is loose, wear, if necessary, replace the chain and adjust the appropriate tension. For couplings, check for looseness, eccentricity, etc., recalibrate and fix.
Replacement of worn parts: When transmission parts (e.g., belts, chains, gears, etc.) are severely worn, replace them in a timely manner. After replacement, the transmission system should be debugged to ensure that the power of the motor can be smoothly transmitted to the winding shaft.
5, excessive mechanical vibration fault
Fault phenomenon
The overall vibration of the equipment is obvious: the winding machine produces violent vibration during operation, which not only affects the quality of winding, but also may lead to other parts loosening and damage.
Vibration-induced noise and precision degradation: Excessive vibration will generate noise, and also reduce the precision of winding, such as the precision of arranging lines, the precision of winding position, and so on.
Solution
Check the equipment installation foundation: Make sure the winding machine is installed on a solid, level foundation. If the foundation is not solid, it will lead to excessive vibration of the equipment. The equipment can be reinstalled and fixed on a stable foundation using, for example, ground bolts.
Balance check and adjustment: Balance check the rotating parts such as winding shaft and motor rotor. If the parts are not balanced, they will generate large centrifugal force and cause vibration when rotating at high speed. For unbalanced parts, vibration can be reduced by adding balancing blocks or making dynamic balancing corrections.
Check the mechanical connection and parts fit: check whether the mechanical connection inside the equipment is firm, such as whether the bolts and nuts are loose; whether the fit between the parts is appropriate, such as whether the fit gap between the bearing and the shaft, the bushing and the shaft is normal. Tighten the loose parts, and adjust or replace the parts according to the actual need in case of improper fit clearance.
※ If you still can't solve the equipment failure by the above ways and means, please contact the technical specialist of Xinhui Mechanical & Electrical Equipment Co.
