July 7, 2022
Automatic Winding Machine
Automatic Winding Machine

Summary:_

This article covers the design of a fully automatic winding machine for stator windings of motors used in submersible pumps. A conventional coil winding machine winds a copper wire around a former (winding fixture). The former is attached to a manually operated sliding arm. However, as these machines typically have material tension limitations, operator intervention and low productivity, and motors are a basic requirement for any job requiring automation, stator winding has become a growing essential process in automation solutions. The machine winds the coil within the slot of the electron. The length of the carapace is 9.2 cm. The number of slots and number of turns per slot is user defined. Winding is done in a suitable way using various components. A three-phase geared induction motor drives the rotation of the sliding arm with an appropriate belt and pulley arrangement. A proximity sensor is used to count the number of turns of the sliding arm. The machine winds 110 coils per minute at 120 rpm. The shifter assembly consists of a series of nylon pulleys to maintain tension and linear alignment. The ball screw mechanism is used for precise slot movement and is driven by a stepper motor. The machine is controlled by a PIC16F877A microcontroller. The required number of turns and slots are provided as input via a keypad displayed on the LCD. When processing is finished, a buzzer notifies you. The approximate cost of the developed machine is greatly reduced.

The main objective of this project is to develop an automatic coil winding machine that can be used for various winding operations, which will greatly reduce the effort of manually operated machines and realize the idea of ‚Äč‚Äčautomation of coil winding machines. This method can also be used to reduce manufacturing costs and increase productivity. This machine can be used to wind coils of wire associated with limited gauges. First, a manual winding method was in practice, which turned out to be very tedious and more time consuming. Therefore, some revolutionary changes were required in the field of winding. Parts produced in this way have a good strength-to-weight ratio and are cost-effective. Manual wire winding should have been the conventional method earlier, but lacked accuracy due to loose or tight wires. Therefore, it was necessary to manufacture the machine for higher accuracy on a small scale. This winding machine is easy to use and portable.