Installation and debugging process of motor embedded assembly line

The motor embedding assembly line is the core link of motor production, which is responsible for key processes such as stator core embedding, winding shaping and insulation detection. The installation and debugging should focus on "process accuracy, equipment coordination, safety and compliance", and the process is as follows:

First, preparation before installation

First, check the site environment: the ground flatness error is less than or equal to 3 mm/m, and the bearing capacity is more than or equal to 600 kg/㎡, so as to avoid the equipment running vibration; The power supply needs 380V three-phase five-wire system (voltage fluctuation ≤ 5%), and the gas source pressure is stable at 0.6-0.8MPa. Check the equipment components according to the drawings, and make sure that the models of core equipment such as wire embedding machine, shaper, bobbin and insulation test bench match the specifications of the motor (such as the number of stator slots and winding turns), and check that the vulnerable parts such as wire embedding die and wire guiding mechanism are free from deformation and burr.

Second, the core installation link

According to the principle of "master first, vice later", the levelness (longitudinal error ≤1mm/m, transverse error ≤0.5mm/m) of each section of the rack is calibrated with a level, and the ground is fixed by expansion bolts. When the embedding machine is butted with the conveying line, the stator positioning fixture should be aligned with the center of the conveying line with an error of ≤ 0.5 mm; The briquetting stroke of winding shaper should match the height of stator to ensure that the flatness error of winding end after shaping is ≤ 1 mm. The wiring of the electrical system needs to separate the strong current (motor) from the weak current (sensor), the PLC control cabinet is installed in a ventilated place, the sensors (such as photoelectric switch and position sensor) are aligned with the stator positioning point, and the detection distance is adjusted to "only identify the workpiece without empty trigger".

Third, debugging in stages

During no-load debugging, start the equipment to run for 30 minutes, check whether the conveying line speed (error ≤ 2%) and the spindle speed of the embedding machine are stable, and stop the machine within 1 second after the emergency stop button is triggered. The trial production of standard stator core for load debugging verifies the embedding process: the wire tension (usually 0.5-1.5N) is even, the windings are not damaged after embedding, and the slots are arranged neatly; The briquetting pressure of the shaper (set according to the winding specifications, such as 5-10kN) is moderate, and there is no winding deformation. The test voltage (e.g. 1000V/1 minute) shall be calibrated during the debugging of the insulation testing platform to ensure that the error of the insulation resistance test value is ≤ 5%.

IV. Acceptance and Delivery

According to the acceptance of General Technical Conditions for Motor Production Equipment, it is important to check that the qualification rate of embedded wire is ≥99.5%, the accuracy of insulation detection is 100%, and the safety protection (guardrail height ≥1.1m, grounding resistance ≤4Ω) is up to standard. Arrange installation and debugging records and delivery of operation manuals, and train operators to adjust embedding parameters and handle common faults (such as wire sticking and sensor false alarm) to ensure stable production line.