Definition：

The core of a motor is to convert electrical energy into mechanical power and achieve rotational motion by utilizing the interaction between magnetic fields and electric currents.

Motor winding refers to the arrangement of electrical conductors in a motor to generate a magnetic field and drive the conductors. The type of winding and the characteristics of the conductors also influence the specifications of the motor. Motor winding assembly refers to the arrangement of electrical conductors between the casing and the rotor of a motor. These conductors are made up of coil with high conductivity and can be used with wires of various thicknesses. The smaller the diameter of the wire, the denser the winding assembly can be. This significantly alters the operational behavior of the motor as it also changes the type of magnetic field generated when current passes through the motor winding.

Function：

The winding assembly of a motor is influenced by the thickness and strength of the wire. The finer the wire, the more winding assemblies can be achieved. This results in the following four consequences:

  1. The magnetic field strength of each winding assembly increases.
  2. Consequently, the torque also increases.
  3. The electromagnetic force in the entire system increases.
  4. This increases the back electromotive force, which offsets the working voltage as speed increases.

The quality of a motor on the craftsmanship of its winding, thus winding machines are highly utilized as production equipment for various electronic and electrical devices, as well as mechanical equipment with higher demands for speed and precision.

  • Customer Demand: Key Component - Fly Fork Shaft
  • Industry: Applied to Automated Motor Winding Machines

Features：

This motor automatic winding machine is widely used in the electronics industry, smart home market, and emerging fields such as charging piles and new energy. It is designed for winding coil with enameled copper wire and is a crucial processing equipment. Therefore, the motor winding machine must maintain high precision. The control system needs to provide very precise, smooth, and flexible wire speed reversal capabilities. This equipment must have high precision positioning and durability, and therefore the key component, the fly fork shaft, plays an important role in it.

What problems did the customer encounter?

The original manufacturing process of the product involved the customer seeking assistance from external vendors to process the core of this shaft. Upon returning to the customer, the product's center of gravity was found to have shifted after processing, necessitating dynamic balance confirmation and subsequent counterweight adjustments . This not only consumed excessive time but also incurred additional labor costs. The main issues faced by the customer were:

  1. The round-trip process consumed the majority of the production time: The finished product couldn't be entirely produced by external vendors, with raw materials processed initially by Vendor A, semi-finished products then passed to Vendor B for intermediate processing, and finally, the customer handled the post-processing to completion.
  2. Difficulty in ensuring stable quality with a one-in, one-out process: Products outsourced to one of the external vendors, and when returned to the customer for post-processing, defects found in semi-finished products couldn't be rectified as dimensions couldn't be altered at that stage.
  3. Excessive time spent on the product's electrical discharge machining process led to low production efficiency. 4.Poor concentricity rate of the product reached 20%, resulting in excessively high procurement costs.
  4. Poor concentricity rate of the product reached 20%, resulting in excessively high procurement costs.

Answer: Solutions provided by Headway! (What challenges were experienced in the manufacturing process?)
Through detailed discussions with Headway, understanding the customer's requirements, we achieved the following:

  1. The customer only needs to correspond with one point of contact: Headway's complete production equipment solved the dilemma of multiple processes of this product being manufactured by different vendors.
  2. Alteration of the process flow: The product was processed to completion before undergoing electrical discharge machining. Additionally, to effectively control the outer diameter dimensions, adjustments were made to the power of the electrical discharge equipment, successfully shortening the processing time by 30% .
  3. With the assistance of the technical team, this product was redesigned to adopt external circular grinding machine top-center processing in the final stages of the production process, significantly enhancing its concentricity precision and perfectly meeting the customer's requirements!
  4. The customer continues to place orders.

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