Faced with complex winding tasks, how does the disc winding machine ensure the close fit between different layers?
Publish Time: 2025-04-15
In complex winding tasks, the disc winding machine is a key equipment, and its performance directly affects the quality and performance of the coil. Especially when multi-layer winding is required, it is particularly important to ensure the close fit between different layers. This is not only related to the electrical performance of the coil, but also affects its mechanical strength and heat dissipation performance.
1. Accurate tension control
Tension control is the primary factor for the disc winding machine to ensure the close fit between different layers. During the winding process, if the tension is too large, the wire may be broken or deformed; if the tension is too small, the wires are prone to looseness, affecting the fit effect. Therefore, the disc winding machine is equipped with a high-precision tension control system that can monitor and adjust the tension of the wire in real time to ensure that it remains constant during the winding process. This precise tension control helps the wires to remain closely arranged during winding and reduce the gap between layers.
2. Optimized winding path design
The design of the winding path is also a key factor affecting the interlayer fit effect. The disc winding machine optimizes the winding path so that the wire can be evenly distributed during the winding process to avoid local accumulation or sparseness. At the same time, a reasonable winding path can also reduce the bending and twisting of the wire during the winding process, maintain the straightness and roundness of the wire, and further improve the inter-layer fitting effect.
3. Advanced wire arrangement mechanism
The wire arrangement mechanism is an important component for the disc winding machine to achieve close fitting. It is responsible for arranging the wire on the disc surface according to the predetermined path and spacing. The advanced wire arrangement mechanism uses a high-precision servo motor and transmission system to ensure the precise position control of the wire during the winding process. By adjusting the parameters of the wire arrangement mechanism, such as the wire arrangement spacing and wire arrangement speed, the arrangement effect of the wire can be further optimized to achieve close fitting between different layers.
4. Application of inter-layer pressing technology
In order to further ensure close fitting between different layers, the disc winding machine also adopts inter-layer pressing technology. When winding multiple layers of coils, after each layer is wound, the wire is slightly pressed by the pressing device to make it fit more closely together. This pressing action not only helps to reduce the gap between layers, but also improves the overall mechanical strength and stability of the coil.
5. Real-time monitoring and feedback adjustment
During the winding process, the disc winding machine is also equipped with a real-time monitoring and feedback adjustment system. The system can monitor the tension, position, arrangement effect and other parameters of the wire in real time, and automatically adjust the operating parameters of the winding machine according to the monitoring results. For example, when it is found that the wire tension is too large or too small, the system will automatically adjust the output of the tension control system; when it is found that the wire arrangement is uneven, the system will automatically adjust the parameters of the wire arrangement mechanism. This real-time monitoring and feedback adjustment mechanism helps to ensure the stability and consistency of the winding process, thereby achieving a close fit between different layers.
