Automatic Winding Machine

Overall dimension: 1700x1260x1750mm (LxWxH)

Input voltage: 220V AC 50/60HZ

Equipment weight: about 650KG

Working air pressure: 0.4-0.7MPa

Rotor outer diameter: Ф23-Ф53mm

Rotor stack thickness: 10-50mm

Rotor shaft length: 50-220mm

Rotor shaft diameter: Ф3.2-Ф12mm

Wire diameter range: 0.08-0.4mm

Flying fork speed: 3500RPM, 2800RPM (rated)

Production efficiency: 10 hooks, 10 slots, 1005 turns, 22 seconds / a

The process flow of a 4-station double flying fork winding machine typically involves several automated steps designed to efficiently and accurately accomplish the task of winding motor rotors or similar workpieces.

1、Workpiece preparation and loading:

The operator places the workpiece to be wound (e.g., motor rotor) in the designated loading position.

The machine may be equipped with an automatic loading system that feeds the workpiece into the work area by means of a robot (optional).

2、Automatic positioning and slot alignment:

After the rotor has been automatically fed, the machine performs a precise positioning of the rotor by means of sensors and positioning devices to ensure the accuracy of the winding position.

For motor rotors, this step usually includes automatic slot alignment, i.e. precise alignment of the winding head with the rotor's slots.

3、Pneumatic pull-in of the winding position:

Once the workpiece is positioned, a pneumatic device (e.g., cylinder) automatically pulls the workpiece into the winding position, ready to begin winding.

4、Automatic winding:

The winding head (usually a double flying fork structure) is driven by a servo motor or stepper motor and automatically winds the wire according to a preset program and parameters.

The double flying fork structure allows for simultaneous winding in both directions, increasing the efficiency of the winding process.

5、Rotor & Hookup:

During the winding process, the rotor may need to be indexed several times to complete the winding of different slots.

When the winding is completed, the machine will automatically hook the winding head to secure the wound coil.

6、Automatic wire clamping and withdrawal:

At the end of winding, the machine uses a wire clamping device to clamp the coil to prevent it from coming loose.

The workpiece is then automatically withdrawn from the winding position.

7、Manual removal of the workpiece:

After the current rotor has been wound and exited, the operator manually removes the rotor for the next process.

8、Cyclic operation:

The machine automatically detects if there is a new rotor to be processed, and if so, repeats the above process; if not, it may go into standby or perform other preset maintenance tasks.

It should be noted that the process flow may vary for different models and sizes of 4-station double flying fork winding machines.

The overall technical program of manual four-station double flying fork winding machine involves many aspects, including structural design, working principle, technical features and application advantages. The following is a comprehensive overview of the technical program:

一、Structural design

1、Machine body and working table

The machine body serves as the supporting framework of the whole equipment, which is stable and durable.

The main working table is located at the top of the machine body and is the main platform for winding operation.

The sub-table may be used for auxiliary operation or for placing parts to be machined.

2、 Double Fly Fork Structure

One of the core advantages of the Dual Flyer Winding Machine is its unique dual flyer design.

Each flying fork is equipped with an independent fixture to hold the wire and guide it through the winding process.

3. Lifting and moving mechanism

Components such as lifting plates and lifting structures are used to adjust the height and position of the workpiece or winding tool to suit different winding needs.

Moving components (e.g. guide rails, moving seats, etc.) ensure flexibility and accuracy during the winding process.

4. Control system

PLC (Programmable Logic Controller) is used to realize the control of the winding process.

The control system integrates sensors, touch screen and other components for real-time monitoring and adjustment of the winding parameters.

二、 Working Principle

1、 Feeding and positioning

The motor rotor is manually placed on the table and aligned by the positioning structure.

The positioning structure includes the cylinder for loading and unloading, limit lever and other components, which are used to ensure the stability of the workpiece in the winding process.

2、Winding operation

The fixture in the double flying fork structure clamps the wire and guides it to wind according to the set trajectory.

The motor drives the bobbin to rotate while the fixture moves automatically to complete the winding process.

3、 Unloading and changing

When the winding is completed, the fixture automatically releases the wire and returns to the initial position to wait for the next operation.

The rotor is removed manually and replaced by another set of rotor for continuous production.

三、Technical features

1、High efficiency

The double flying fork design dramatically improves the winding efficiency, resulting in a significant increase in production per unit of time.

2、Precision

Precise mechanical structure and advanced control system ensure the accuracy and consistency of the winding process.

3、Flexibility

Applicable to a wide range of materials and specifications wire winding needs, material adaptability.

4、Automation and Intelligence

Highly automated working method reduces labor cost and improves production efficiency.

Intelligent control system can monitor and adjust the winding parameters in real time to ensure the stability of winding quality.

四、Application Advantages

1. Improve production efficiency

High efficiency and high precision winding process makes the production cycle shorter and improves the overall production efficiency.

2. Reduce production costs

Automation and intelligent production methods reduce labor costs, while reducing errors and waste caused by human factors.

3. Improve product quality

The winding process and stable winding quality help to improve the overall performance and service life of the product.

4. Expanding application area

Double flying fork small micro-rotor winding machine has a wide range of applications in electronics, communications, automotive manufacturing and oth

This machine is used for all kinds of micro-motor rotor hook commutator winding equipment, this machine is the use of double flying fork winding at the same time, good balance, one time winding four rotors, greatly improve the winding efficiency.

When winding, the wire rod is automatically pulled at the end and tail of the wire, and when the machine is rewound on four rotors at the same time, it can be put into four rotors for winding; One side of the winding is taken out, one side is automatically loaded, and so on.

The length and short rotor height adjustment parameter setting is simple, easy to replace the hook angle conversion, the clamp length and short rotor are adjustable and universal, easy to convert, and quickly replace the winding die and fixture. Manual and automatic switching (for maintenance and model changes).