The application of Omron tension control in automobile motor winding

Process introduction

In recent years, the motor industry has shown a rapid upward trend, new products, new technologies are constantly updated and iterative, resulting in increasingly fierce competition between motor manufacturers, how to improve equipment performance, improve productivity, is the current motor manufacturers need to solve the problem.

The application of Omron tension control in automobile motor winding

　　Motor manufacturing process

Among the many processes described above, the winding process is one of the most important processes, and it is also the key to improving the overall equipment performance and increasing productivity.

　　problem

1. The winding quality is unstable

When the winding accelerates or decelerates, that is, when there is a drastic change in speed, the tension of the wire is prone to change, which leads to uneven winding phenomena such as gaps and overlaps.

2. Winding trajectory offset

The 5 axes are synchronized and controlled, and due to the different phases of each axis and the main axis, the winding trajectory may be offset due to delay, and uneven winding may occur.

　　solution

1. Optimization of acceleration and deceleration curves

By using the Jerk setting in Sysmac Studio, the curve (S-shaped) during acceleration and deceleration can be changed, which suppresses drastic speed changes, improves the uneven winding gap that occurs at high speeds, and increases the number of coils per minute by 200%.

　　2. Realize the high speed of winding through delay compensation

The amount of compensation calculated based on the delay time of each axis is increased to the original instruction value. In addition, by matching the delay time of each axis, it also avoids the internal winding of the spray line and prevents contact with the gears, etc., and finally realizes the high-speed winding, which reduces the defect rate by 20% and increases the energy density by 10%.

　　Control system

Through the mechanical automation controller NX102-1200 to do 5-axis synchronous control, Sysmac platform integrated electronic cam and interpolation function to facilitate program editing, machine interface NA series can use the label function, convenient for users to carry out the secondary development of the program, AC servo system 1S series inertia to meet customer needs, and the bus form response speed is fast, anti-interference ability is strong.

　　Deliver value

1. Winding speed:

From 300 rpm

To 600 rpm

2. Winding quality:

20% reduction in defect rate and 10% increase in energy density

3. Maintenance cost:

The program and control scheme are all open, reducing the programming time, the secondary development is simple, and the maintenance time and cost are shortened by 20%.

【Management】

In response to the fierce competition in the current motor industry, through the optimization of the control scheme and the optimization of the program, the efficiency of the winding is increased by 200% to 600 rpm, creating the top competitiveness of the industry.

【Management】

The improvement of the speed and accuracy of the winding is completely based on the optimization of the control system and program, without changing the mechanical structure and movement time, and the introduction time is faster and the cost is lower.

【Engineer Layer】

By matching the delay time of each axis and calculating the amount of compensation, it is possible to avoid the in-winding of the spray line and contact with the gear, etc., and realize the high-speed winding and reduce the defect rate by 20%.

The program and control scheme are all open, reducing the programming time and making the secondary development simple.

Article source: Omron Industrial Automation Information Account

The application of Omron tension control in automobile motor winding

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