Stator production

Types of stator production machines

Stator production is one of the core components of an electric motor and generator. There are several production methods available for stators, including:

• Automatic Lathes

  Automatic lathes used in stator production can be utilized for machined stator components. Typically, CNC (computerized numerical control) lathes have a cutting tool driven by computers to create various machined parts with an elevated level of accuracy.

• Coating Production Line

  The coating production line works with the assistance of robotics, thereby creating an automated process for stator manufacturing. In this type of stator production line, the coatings can be applied to stator components according to specific qualities and standards. The robotics strengths and effectiveness of the coating process are increased by precision techniques and programming, ensuring that the coatings are uniformly applied and that the stator components fulfill their performance criteria. The need for manual labor is decreased as the production line becomes more automated, which can lead to higher production rates, improved consistency, and streamlined operations.

• Flexible Manufacturing Systems (FMS)

  FMS provides a more adaptable stator production system than standard production lines. The basic element of FMS consists of a variety of computer-controlled machining equipment, such as lathes, milling machines, and drilling machines, as well as production equipment like as material transport systems and storage systems. These components work together to create an integrated manufacturing system that can be programmed to carry out a variety of machining processes on various types of product materials. This allows for flexible manufacturing capabilities. The technology for computer control and automation allows for remote control and automated operation of the entire manufacturing process. It not only has great flexibility and adaptability to different product materials and machining processes, but it also has high efficiency and precision, which can meet a variety of machining needs and quality standards.

• Robotic Cells

  In this type of stator production machine, robots are typically used as the main stator creation unit. Robotic cells can undertake handling, assembly, welding, and other operations after being programmed and outfitted with the proper tools and accessories. The flexibility and adaptability of robotic cells allow them to execute a variety of duties in the stator manufacturing process, providing for rapid changeovers and scalability to meet different production needs.

• Gear Hobbing Machines

  Generally, gear hobbing machines are used to cut gears in stator components. A gear-cutting technique called gear hobbing entails using a hob, a particular kind of rotary cutter, to produce gear teeth by rotating it on the gear blank. The gear profiles of various complexity levels may be produced using gear hobbing machines. Moreover, it is possible to shape the gear teeth with high precision and efficiency.

Specifications and maintenance of stator production

Specifications

• Design: Electromagnetic core with laminates or stacks, bobbin or slots for winding, and end bells or supports for mounting the rotor, together form the basic stator design. The precise mounting points and alignment features are also included, which are vital for ensuring a proper fit and alignment with the rotor.
• Technological features: The advanced stator components may include sensorless vector control technology to ensure that the motor performs with the utmost efficiency and reliability. It may even encompass integrated cooling systems and built-in fault diagnostics or self-analysis capabilities, where the stator is able to detect any potential issues within itself, and warn the user before any condition worsens. This can help in predictive maintenance and reduce motor downtime.
• Sizes and loads:Stators can generally come in designated sizes such as 0, 1, and up to 20, and in small to heavy loads, e.g. small domestic appliances such as fans and washing machines, etc. and medium, larger, or industrial-scale use such as for electric motors, servo motors, or power tools, etc.
• Production methods:Usually there are die-cast or hot copper stator manufacturing processes and tech features.

Maintenance

• Clean and dry the machine: Keep the stator's appearance clean and wipe off the dirt frequently. Keep the stator dry, clean, and free of impurities during the assembly process. Making sure the working environment is in clean air can reduce carbon deposits on the cylinder and gasoline valve intake.
• Stator and crankshaft oil seal replacement: Replacement of stator oil seals can prevent engine oil leaks and reduce engine noise during operation. It can also improve the engine's overall performance and longevity. A consistent replacement cycle for oil seals can be adjusted according to the frequency and intensity of engine use, as well as the type of oil seal and its quality.
• Protect the crankshaft: Protect the crankshaft by properly securing it during storage and handling. This prevents damage to the crankshaft and ensures its proper function upon installation in the engine. Appropriate measures include using protective covers, cushioning materials, and secure storage methods that minimize exposure to contaminants and physical damage.
• Coil cleaning: Regular coil cleaning, rather than replacing the entire stator, can help to maintain the performance and function of the stator, thereby improving the overall efficiency and longevity of the system. This approach can be more environmentally friendly and cost-effective by reducing waste and the need for new materials.

Scenarios of stator production

• Electric vehicle industry:

  As electric vehicles continue to gain popularity, the stator will play a crucial role in the production of EV energy converters and drive motors. This presents a massive opportunity for the market to flourish in the years to come.

• Green energy markets:

  Wind and hydro energy production heavily rely on generators, which consist of rotors and stators. The stator is the stationary part of the generator that produces electric current. With the rapid growth of the wind energy market, there is a high demand for stator production for wind power generators.

• Traditional automobile industry:

  The automobile industry's constant demand for motors creates an ever-increasing need for stator production.

• Home appliance industry:

  Many home appliances such as air conditioners, refrigerators, washing machines, and water pumps require motors. As a result, there is a massive demand for stators to support motor production.

• Industrial automation:

  Industry now widely uses motors for driving and regulating. Stator production is a frequent demand for various motors used in industrial automation.

• Robot manufacturing:

  Robots require motors for their movement and functioning. The motors are comprised of rotors and stators. The production of robot stators is in demand to meet the growing robotics market.

• Medical device market:

  Some medical devices such as ventilators, pumps, and imaging equipment need motors to work. Hence, there is a demand for stator production to support motor production for these medical devices.

• Other emerging industries:

  Emerging industries such as artificial intelligence, virtual reality, and the Internet of Things also drive the need for stator production. This is because motors are essential components of machinery and equipment used in these industries.

How to choose stator production

Apart from knowing the correct stator production process, buyers also need to know the factors to consider when choosing a stator manufacturing machine.

• Degreasing unit: Select a degreasing machine with a vaporization or spray process. The machine should be able to use aqueous or non-aqueous solutions and have a neat vaporization ratio of over 10: 1. Choose a unit that offers flexible containment for various coil designs, and opt for a preheating feature for quicker processing times.
• Automatic binding: Go for an automatic binding machine that can perform various operational methods. The operational methods may involve self-tying, crimping, or applying thermoplastic binding. Such a unit should be able to support the stator windings' production for more than 15,000 parts yearly.
• Coating units: This is the stator production machine that applies coatings to the stator windings. The coating may be thermal-set epoxy, polyurethane varnish, and other coating types. Select a coating unit that can meet the desired encapsulation quality and offer a variety of coating types.
• Curing oven: Select a curing oven that can encompass the coil's requirements and its coating type. It should have precise temperature control and uniformity to meet the encapsulation's curing requirements. Also, the curing oven should have efficient insulation and temperature regulation for energy-saving.
• Automatic de-binding: It's important to select an automatic de-binding unit that can perform various methods of operation, such as unscrewing, un-crimping, or un-binding. This unit should have a precise coil holding fixture, suction tooling, and camera identification for selecting and holding the coil.

Q&A

Q1: Which material is used for stator production?

A1: The stator of an electric motor is usually manufactured using a high-silicon special steel alloy. The material selection for the stator determines not only the overall performance but also the stability when in use.

Q2: How long does the stator take to charge?

A2: The average charge time for a stator battery is approximately 8-10 hours.

Q3: What are the reasons to buy electric stator production?

A3: The electric stator can serve several reasons. When the rotor spins, the stator creates a magnetic field that transfers current, which is the basic working principle of motors. Stators are found in various motors, including brushless DC motors, AC synchronous motors, asynchronous motors, etc., so buying them makes sense for businesses that need constant supply and depletion.

Q4: What does the stator consist of?

A4: The stator consists of the following parts: Armature, Windings, Core, Yoke, and Bearing.