Stator Assembly

Stator assembly involves several critical processes, including pressing the stator core, stator coils, stator and motor housing, and stator copper sleeves, etc. Each step requires precise control of force and speed to ensure proper fit and tightness. Therefore, high precision in the press-fitting equipment is essential.

Key Technical Challenges in Stator Assembly

1. High Precision Requirements: The precision of stator assembly significantly impacts the motor's performance:

·         Uneven fit clearance between the stator core and windings can disrupt the electromagnetic field distribution and intensity, reducing the motor’s power due to diminished electromagnetic performance.

·         Uneven clearance between the stator and rotor or insufficient fastening of the stator core can lead to vibration and noise during motor operation. Excessive mechanical and thermal stress during operation accelerates motor aging and damage.

·         Poor contact between the stator core and windings can cause inefficient heat dissipation of the current-induced heat, increasing the motor's temperature and shortening its lifespan.

2. Quality Control Challenges: Stator assembly involves multiple precision components and complex steps. Since the pressing process is typically continuous, it becomes challenging to dismantle and re-check after completion. This makes identifying and correcting critical issues or defects in the process difficult.

Rigorous inspection and monitoring of components are required to ensure compliance with design and quality standards. Real-time monitoring and recording of the pressing process are also necessary to identify and resolve quality issues promptly.

Advantages of Servo Press Machines in Stator Assembly

 1. Position Accuracy Control for stator assembly: To avoid defective products caused by assembly errors, servo presses utilize servo drive technology to adjust motor speed, direction, and torque, controlling the displacement and speed of the press head. With a positioning accuracy of ±0.00005 inches, precise alignment of stator components during pressing is ensured.

2. Force Control for stator assembly: Servo presses prevent overpressure or insufficient pressure, which can damage stator attachments and motor cores. The pressing force is controlled with high precision (0.05% F.S.–0.1% F.S.) through servo motor speed and torque, avoiding excessive impact and vibration during the process and ensuring correct fit clearances.

3. Quality Control for stator assembly: Real-time pressure monitoring: High-precision pressure sensors continuously detect pressure variations during the pressing process. Pressure signals, sampled at rates over 4000 times per second, are fed back to the control system for parameter adjustments.

·         Process Monitoring and Data Recording:

·         Pressure and displacement changes are monitored in real-time to automatically determine product quality, eliminating additional inspection steps and reducing labor costs.

·         Position curve data is saved, and pressing data is fully recorded for traceability. Once sampled, operation recipes can be saved for reuse, meeting diverse process requirements.

·         Multi-mode Pressing Support: Servo presses support flexible configurations for parameters like position, pressure, signal input/output, delay, and press-fit evaluation. Multi-stage composite pressing can be implemented, making them suitable for automated production lines.

High Speed DSP  

The stator is a crucial component in different kinds of electric motors, generators, and other electrical devices, converting electrical energy into mechanical energy. The quality of stator pressing directly impacts the equipment's overall performance. Therefore, selecting suitable equipment for stator processing is a critical prerequisite.

XIRO has mature solutions ranging from precision pressing to complex automated production, backed by experience from thousands of successful cases on stator assembly production lines. If you would like to learn more, please contact us.