The modular single teeth winding for stator，sets a new standard for high-efficient production

As the elevator industry demands higher-speed, larger-capacity, and lower-noise traction machines, the stator, as the "power heart" of the traction machine, its winding process precision, efficiency, and cost control have become the key to a company's core competitiveness. The traditional whole-round winding process has come up with some problems, including material waste, complicated changeover, insufficient coil size precision, which are difficult to meet the high standards of modern traction machine manufacturing. This new development of modular single teeth winding for stator is bringing all-round production innovations to the traction machine industry with the innovative logic of "Breaking down the whole into pieces".

Core innovations

The traditional whole-round stator winding process requires one-time winding on a complete stator, which not only faces difficulties in wire arrangement due to the slot space limitation, but also has problems such as low material utilization and high repair costs.  Once any of the winding coil goes wrong, the entire stator is often scrapped. The modular single teeth winding completely overturns this traditional process by disassembling the stator lamination stack into multiple standardized single teeth modules. Through the process alignment of "disassembly - winding - assembly", it achieves multiple breakthroughs:

• No space constraints for winding: Each single teeth module is small in volume and light in weight, allowing for precise arrangement of concentrated windings and avoiding the problems of wire squeezing and insulation layer damage in the traditional whole-round winding process.

• Significantly reduced material waste: Single teeth stamping does not require the material buffer of whole-round shape, and the utilization rate of scraped materials is significantly improved, greatly increasing the total material utilization rate.

• Failure loss under control: If there is a problem coming from one single teeth coil, we could only replace this coil, instead of scrapping the entire whole stator.  This way significantly reduces the production costs.

Advanced Configuration

A customized block winding solution for stator production of traction machines, featuring high-specification configuration and intelligent design, achieves a triple reliable leap in precision, efficiency, and stability:

1. High-precision control, meeting the demands of high-speed traction machines.

Equipped with renowned brand motion control cards, the winding shaft positioning accuracy and wire arrangement accuracy could reach the industry's high-end level.

Combined with servo tensioners, the tension control is precise and stable, suitable for various gauges of enameled wires, ensuring uniform winding turns and tight arrangement, perfectly matching the strict requirements of high-speed elevator traction machines for cogging torque.

2. Multi-station collaboration, doubling production efficiency

Adopting a multi-station design, it can simultaneously wind multiple stator blocks, significantly improving efficiency compared to traditional full-round winding machines.

Supports multiple program storage.

The entire mold replacement and debugging are convenient and fast, greatly enhancing the changeover efficiency. When loading and unloading manually, the equipment can continue winding, achieving a continuous production mode of "Machine running while personnel rest".

3. Dual guarantees of safety and maintenance, reducing production risks

The equipment is equipped with safety light curtains, emergency stop buttons, and interlocking protection devices. When operators mistakenly enter the dangerous area, the machine can stop instantly, meeting international safety standards.

The core components are equipped with high-quality and brand-name parts. The modular design makes it easier to replace the vulnerable parts, resulting in a low failure rate and simple maintenance, effectively reducing downtime losses.

Value realization

For Nidec Elevator Motors, the value brought by the block-type winding of the stator goes far beyond the upgrade in craftsmanship. It is also reflected in the optimization of the entire cost chain and the enhancement of market competitiveness:

• Significant reduction in labor costs: The fully automated block winding process can replace multiple skilled workers, and there is no high skill operation threshold, which significantly reduces the costs of human management and training.

• Energy consumption and material savings: This centralized winding design significantly reduces the amount of enameled wire used, combined with an efficient servo system, the operating energy consumption of the equipment is significantly lower than that of traditional equipment.

• Improvement in quality stability: The defect rate of winding is kept at an extremely low level, the one-time qualified rate of the finished products remains high, reducing the delays and rework costs caused by non-conforming products.

Conclusion

From "whole-circle winding" to "block-style winding", the technological transformation of stator winding processes is essentially a reflection of the traction machine industry's transition towards intelligent manufacturing and flexible production. This innovative process, which combines high precision, high efficiency, and low cost, not only resolves many problems of traditional processes but also helps Nidec Elevator Motors quickly respond to the demands of multiple varieties and small batches of the market, seizing the initiative in the fierce industry competition.

In the future, with the integration of industrial Internet of Things technology, the Nidec Elevator Motor team will achieve more intelligent functions such as real-time production data monitoring and remote error diagnosis, continuously injecting power into the high-quality development of the traction machine manufacturing industry!