Fully automatic flat wire super large square vertical winding machine

1. Introduction

In the manufacturing fields of new energy motors, industrial frequency converters, and ultra large transformers, the flat wire vertical winding process is gradually replacing the traditional round wire winding technology. The birth of the fully automatic flat wire super large square vertical winding machine has broken through the technical bottlenecks of traditional winding equipment in three dimensions: cross-sectional area (up to 1000mm ²), winding accuracy (± 0.1 ° angle control), and production efficiency (300% higher than traditional processes), becoming the core equipment for high-end electromagnetic component manufacturing.

2、 Analysis of core technology of equipment

1. Ultra large cross-sectional area winding system

Material adaptability: Adopting multi-stage tension collaborative control technology, it can handle copper/aluminum foil strips with a thickness range of 0.5-10mm, a width of up to 150mm, and a single turn cross-sectional area exceeding 1200mm ².

Vertical winding architecture: By using a vertical spindle and a 3D servo platform, precise stacking of conductors in the Z-axis direction is achieved, and the interlayer insulation spacing can be controlled within 0.05mm.

2. Fully closed-loop intelligent control system

Six axis linkage technology: integrates the coordinated motion of the winding spindle, feeding manipulator, clamping device, and angle corrector, and achieves μ level motion control through industrial grade PLC (such as Siemens S7-1500).

Machine vision assistance: Using a 5-megapixel CCD to monitor the edge position of the conductor in real time, combined with AI algorithms to automatically compensate for deformation errors caused by material ductility.

3. Modular process database

Pre installed new energy motors (such as permanent magnet synchronous motors), reactors, transformers, and more than 20 winding modes, supporting direct import of CAD drawings to generate machining programs, reducing changeover time to 15 minutes.

3、 Typical application scenarios

1. New energy vehicle drive motor

Provide a low loss winding solution for 800V high-voltage platform motors, which has been tested to reduce AC losses by up to 40% (compared to traditional round wire motors).

2. Wind power inverter reactor

Realize automated production of super large square reactors weighing up to 2 tons per unit, reducing the number of manual interventions from 50 times per unit to 3 times per unit.

3. Traction Transformer for Rail Transit

Meet the continuous winding requirements of 2500kVA transformers under EN 60310 standard, with a temperature rise reduced by 15K compared to traditional processes.

4、 Industry Value Analysis

1. Cost Revolution

Taking the electric motors of new energy commercial vehicles as an example, the material utilization rate has increased from 92% to 98%, saving approximately 1200 yuan in copper material costs per motor.

2. Quality leap

By using a laser rangefinder to monitor the tightness of the winding in real time, the pass rate of the product's 2000V/1-minute withstand voltage test has increased from 85% to 99.7%.

3. Green manufacturing

Integrated waste recycling system reduces copper chip production by 70% and meets ISO 14001 environmental standards with oil mist collection device.

5、 Technological Evolution Direction

1. Digital twin system: The virtual debugging module under development can simulate the winding process in advance, and is expected to reduce trial machine losses by 60%.

2. Superconducting material adaptation: Reserve a -196 ℃ liquid nitrogen environment interface to prepare for future high-temperature superconducting motor windings.

6、 Conclusion

This vertical winding machine not only solves the problem of forming large cross-sectional conductors, but also achieves unmanned production at the "black light factory" level through MES system docking. As silicon carbide devices drive the development of motors towards high frequencies, the demand for flat wire windings will continue to explode, and this equipment is expected to become a standard equipment for high-end motor manufacturing in the next five years.