Winding and fusing technologies of electric motors are a key element to grant high efficiency and functions for “white goods”. Paying particular attention to automation, user-friendliness and lower maintenance costs.
Manuela Gioberti
Essential in the white good world, the winding and fusing technology of an electric motor represents, today more than ever, one of the key elements in the choice of a plant supplier. The commercial success of the finished product depends in fact on it, in particular for those markets needing continuous improvements of the product performance. According to this market need, Atop, headquartered at Barberino Val D’Elsa (FI), has developed the new winding-fusing machine model TWF-8A, very appreciated by the household appliance sector for its features of quality, productivity, flexibility and reliability in the production of electric motors.
Automatic operation
Very user-friendly and intuitive, the winding-fusing TWF-8A self-adjusts its machining processes so that, at the changeover, all parameters of winding, wire tensioning and fusing are automatically restored by recalling a formula.
The management operator interface occurs through a touch-screen terminal; motors are Siemens state-of-the-art. High rapidity also in the change of winding and fusing equipment, without needing any regulation. The loading/unloading process occurs with controlled axis so that it is not necessary to vary mechanical stops or to make adjustments at the changeover, while the positioning error compensation of the loaded armature occurs through the measurement of the commutator position, for an always-perfect loading in compliance with the commutator on the index clamp.
Compact and smart
The machine software includes a programming menu able to satisfy all configuration and winding requirements that are feasible until now; they describe indications for preventive maintenance according to the operation hours, guided instructions for the changeover and detailed indications for the troubleshooting, including possible problem-solving suggestions. The space optimization matches two processes in a single machine, allowing the use of a more compact (then cheap) and efficient transport system, with higher process safety in case the machine has a manual feeding of armatures. The full accessibility in the winding/fusing zone allows carrying out maintenance interventions in fast and simple way, under safe conditions.
Maintenance is not necessary
Hollow shaft motors, with direct mesh assembly on the flyer, allow lower inertia, higher compactness and no maintenance intervention thanks to the reduction of the parts undergoing wear, like belts and pulleys. The jaw tool is fixed in vertical position through system with gear satellite group in sealed box that needs no maintenance; the wire
wear measuring occurs by encoder; through this system it is possible to survey the wire failure, the winding out of slot, the missing coupling to the commutator, the wire not cut by the gripper, or the inhomogeneity in the wire consumption between the two flyers (indirect balancing control). The electronic armature index is directly mounted in the winding zone; an appropriate hopper, adequately connected, collects the wire wastes. The electronic wire tensioning devices integrated into the machine have the possibility of applying differentiated tensions during the various winding phases (hooking, acceleration, winding and braking). The load cell allows the control of the wire tensioning and the possible compensation of the current applied to the brake. The arm for the wire recovery is kept in constant position by a proportional valve.
Welding under control
TWF-8A recognizes the hooks with initial and final wires, offering the possibility of applying a welding programme dedicated to them, different from that used for the other hooks. The AWI-100 welding control with “inverter technology” allows a DC welding at constant power: the main advantage of this device consists in the management and coordination of all the functions concerning the welding process. The welding control is integrated into the machine terminal, thus improving performances and response times. This welding cycle allows a longer service life of electrodes, thanks to the optimization of the power applied to hooks with a single wire.
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