这是一种近几年发展起来的绕线技术： 针式绕线机 Needdle winding machine，

厦门米特开发的针式绕线机，可用于无刷电机的定子绕线、无刷电机的转子绕线，油泵电机的定子内绕机，以及其他各种电机的内绕或外绕。

型号：MTNR-01/02/04/06 的无刷电机转子绕线机外转子针式外绕机设备，适用于航模、医疗器械、家用电器、电动车等多个领域的无刷电机外转子绕线。采用双工位针式外绕设计，人机界面具有故障诊断、产量计存等功能，配备伺服电机控制系统实现产品绕制，可根据客户需求设定自动绕线、多线径绕线、自动分度、自动跨槽、绕线速度等参数设定；每次动作循环将绕制多个无刷转子，操作简单，生产效率高等特点。

型号：MTWR-01/02/04/06无刷定子针式内绕机特别适用于油烟机电机、卷发器电机、伺服电机、无刷家用电机、步进电机、风扇电机、、吊扇电机、无叶风扇电机，无刷电动工具，无刷医疗器械等各类直流无刷电机。定子绕线设备采用双工位同时自动绕线，自动抽头、自动挂线，自动夹线剪线，自动排线，自动过线。

Unlike the previous winding processes, the term needle winding technology is not derived 

from the type of wire placing, but rather from the geometric structure of the wire guide 

respectively the nozzle. The wire guide, which acts like a needle, directly navigates along 

the placement contour around the bobbin. Opposed to other winding processes, the needle 

winding technology has longer nozzles, which are adapted to the part which is to be wrapped.

Similar to flyer winding technology, the bobbin is typically tightly clamped. Needle 

winding systems, which clamp the bobbin but allow a rotational motion, are an exception. A rotary motion of the part is always necessary for wire placement. This is why there 

are pivoting needle carriers. The wire is not placed by a circular motion, but on a direct 

course along the winding geometry. The termination of individual turns, which depends 

on the product geometry, is usually manufactured fully automatically. This is why this winding process is very cost-effective and reliable even for high numbers of poles. The needle 

winding technology is mainly used for products with thicker wires and lower numbers of 

turns. Hence it is opposed to the flyer technology, where thin wires and high numbers of 

 

turns can be processed economically

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For better 

wire guidance, auxiliary tools may be used, as shown in Figure 3.62. Aside from guiding, 

they also pre-shape the wire. In accordance with the Bauschinger effect (Section 3.1.1), the 

 

wire can be bent in the opposite direction more easily

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A space the size of the nozzle diameter or the nozzle width has to be left between neighbouring poles, which is a disadvantage. The nozzle diameter or nozzle width is about three 

times the wire gauge. By using oval nozzles or nozzles with a trumpet-shaped opening, the 

relation of slot width and wire gauge can be reduced. The space between two neighbouring 

poles can therefore not be filled completely. An exception to this is guiding the wire outside 

of the slot, in order to utilise the remaining winding space. In this method, the precision 

of the wire guiding depends on the residual guiding properties of the wire. Currently, a 

special type of needle winding technology is being developed for the direct winding of 

distributed windings for larger stators. A new kinematics for more complex placing of the 

 

connecting wires is illustrated in below Figure.

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A space the size of the nozzle diameter or the nozzle width has to be left between neighbouring poles, which is a disadvantage. The nozzle diameter or nozzle width is about three 

times the wire gauge. By using oval nozzles or nozzles with a trumpet-shaped opening, the 

relation of slot width and wire gauge can be reduced. The space between two neighbouring 

poles can therefore not be filled completely. An exception to this is guiding the wire outside 

of the slot, in order to utilise the remaining winding space. In this method, the precision 

of the wire guiding depends on the residual guiding properties of the wire. Currently, a 

special type of needle winding technology is being developed for the direct winding of 

distributed windings for larger stators. A new kinematics for more complex placing of the 

 

connecting wires is illustrated in below Figure.

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设备特点：

1.  这种内绕机通过驱动线嘴上下运动和铁芯摆动进行绕线。

2.  可调整每层绕线的线嘴高度，从而可以降低线包的高度。

3. 自动缠线头线尾，自动绕线，自动排线，自动转位，自动夹剪。

4. 采用伺服精准定位，绕线，排线，转位。

5. 有单头、双头或四头几种机型，也可根据客户产能要求定制更多绕线头。

Due to a variety of product categories, there are many diff erent types of manufacturing 

machines in needle winding technology. Special types of needle winding have been established for the high demand of diff erent motors with relatively thick wires and high fi ll 

factors. For the geometry of a stator it can be crucial whether the stator blank is picked up 

 

vertically or horizontally, and which dynamic targets can be achieved .

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 Applications

One distinguishes between three areas of application in needle winding technology. These 

application areas comprise a product category with externally grooved stators, internally 

grooved stators and pole chain winding, respectively. Needle winding technology is not 

suitable for traditional circular, quadratic or rectangular cylindrical single coils, as other 

technologies work much more economically for these types of coils.

Therefore, stator winding is of great importance in needle winding technology. Similar 

to flyer winding technology, all of the placement motions for this process are executed by 

the wire guide. However, the rotation does not take place via a circular motion. Instead, 

the wire is directly placed along the stator or the circumference of the tooth. The resulting 

dynamic requirements are a challenge for the manufacturing machines and, in comparison 

to other processes, limit the number of turns per minute.

Pole chains are multiple, linearly arranged and attached single-poles which are assembled to a stator after winding. Due to the existing connection, the single-poles just have to 

be arranged as a circular stator shape.

The vertical arrangement of stators is often limited in that wires can horizontally be 

placed more evenly in very long grooves from a dynamic point of view. For very short 

grooves and therefore short placing strokes, a mechanical cam control or synchronized 

servo drives are used for high winding speeds. For chain winding, special needle winding 

 

machines are designed, which are adapted to each winding task in their systematic structure.

The basic setup of needle winding systems, including the placing gear, can be standardised in most cases. This has certain levels, depending on the number of simultaneously 

manufactured stators and their size. This shows that even in needle winding technology a 

duplication or multiplication of wire guides can be economically reasonable. The larger the 

processed wire gauge is, the higher are the forces that are applied, and the machine has to 

be designed with a higher stiffness. Due to the high utilization of manufacturing machines, they are often equipped with exchangeable parts or sub-assemblies, in order to wind 

different products. The limitations of stator manufacturing are lying in the groove width 

between the pole shoes, and therefore are defined by the distance between stator teeth or 

stator length.

Wire feeding and wire course to the wire feeder

Similar to the previous processes, the wire is pulled from a supply spool and fed to the wire 

guide via a wire tension control system. For winding of externally grooved stators, which 

are wound vertically, and chain winders, the wire supply is often located outside the manufacturing machine (Figure 3.59). This can prevent unnecessary diversions which would 

have a negative impact on the wire quality. The control systems are usually designed to a 

certain wire gauge range and must be adapted to each winding task.

The lubrication of enamelled copper wire has a very important task in needle winding 

technology. Since the friction forces which act on the wire are reduced with the lubricant, 

it should be carried along up to the wire’s actual placement to protect both the tools and 

the machine.

The wire guide or needle carrier

In needle winding technology, there are special requirements for the wire guide. The needle 

is often designed to be longer than in other winding processes due to the handling deep 

inside the pole shoe. The wire guide nozzle is referred to as needle in this technology. The 

inner diameter is adapted to the wire guide. It has a highly polished surface and a significant influence on the winding quality. The wire often exits the needle at sharp angles and 

is at this point highly strained, just like the needle. To terminate and place the wire on the 

stator face side, the needle must be pivoted around an angle. This is especially challenging 

for internally grooved bobbins, as the stator determines the installation space for the wire 

guide. When winding tooth chains with linearly arranged pole shoes, three phases can be 

wound at the same time. Connecting by terminating after the winding process is unusual 

for pole chains, as this is done with other technologies after rounding the stator. As multiplication of the wire guide is possible in needle winding technology, multiple stators and 

phases can be wound at the same time. An adaptation of the other sub-assemblies of the 

machine, however, must be taken into account. For all needle winding processes the critical measure between the pole shoes must be considered. This also has an impact on the 

dimensions of the wire guide nozzle. Figure 3.60 shows the design of the needle carrier.

Fixtures

When considering stator fixtures, different product categories can be distinguished. Fixtures for externally grooved stators grip inside the part. Due to the imbalance properties 

of the part, they are comparable to those of turning parts, but are not as critical because of 

lower speeds. Accordingly, internally grooved parts are gripped on the outer diameter, and 

are therefore constructed more elaborately in most cases.

After each winding, the stators are switched from one pole shoe to the next via a switching gear or a CNC turning axis. A rotational fixture designed as force-fit or form-fit must 

generally be taken into account. Usually, product specific fixtures are intended for manufacturing single-teeth, respectively concentrated windings or stator chain windings. Initially, the internally grooved stators are aligned linearly before later being rounded. During 

the winding process, they are lined up like a chain and fixated on their circumferential surface, so that the pole shoe is accessible from all directions necessary for winding. It should 

be ensured that the parts which are to be wrapped are fixed well, so that the force applied 

by the placing is well absorbed by the tooth. To enable convenient loading and unloading, 

an easy clamping must be provided for both manual and fully automated processes. These 

special tools must also be of high manufacturing quality.

Fully automated winding process

For product manufacturing with needle winding technology, the wire is also fixated at a 

starting point. This can be an external wire park pin or a contacting post on the tool, or 

the stator. The difference to other winding processes is the processing of thicker wires. 

In this process, the loose wire end has a relatively stable shape due to its high stiffness, 

which does not necessarily demand clamping between the winding processes. Based on 

the motion sequence during placement, the switching gear axis can directly support the 

operating procedure and take over the rotational motion, as long as it is controlled by a 

servo motor. To prevent the needle from touching the stator, a precise synchronisation of 

the rotational motion and the stroke motion is necessary. Influencing factors for the maximum winding speed are, among others, the needle stroke, the stator rotational angle defined by the number of poles, the wire gauge, and the slot width. A special role is assigned to 

the pitch angle of a stator with pitched grooves. Both servo motoric rotational axes and a 

communication between two axes is necessary in order to ensure a proper motion profile. 

This also has an impact on the manufacturing times. Since the distribution of the stroke 

length to the rotational motion of the stator is significant, and the servo drives must constantly reverse in order to generate the reversed needle motion, a crank disk can be used. 

The initiation of the stroke motion is transferred to the crank disk via a rotational motion, 

which should contain a stroke adjustment, in order to achieve the benefits of a sinusoidal/

semi-circular motion sequence. Depending on the design, up to 2,500 strokes per minute 

can be achieved. As the wire guide nozzle can be moved freely, the wire termination on the 

contact point can be performed with an additional pivoting of the nozzle. Similar to traditional linear winding technology, a contact pin or a lug is used to connect the individual 

poles with either a star or a delta connection. During the process, the combined weight of 

wire guide and needle carrier may lead to undesired vibrations due to the axis acceleration. This, in turn, can influence the winding quality negatively. Accordingly, alternative 

materials from steel are considered. By using the needle winding technology it is possible 

to manufacture whole sub-assemblies, including stator coils, wiring, and contacting on 

a single machine. As opposed to insert technology, and aside from the not fully utilized 

space between the poles, it is possible to wind motor coils on lower lamination stacks with 

smaller winding heads, which have a good fill factor.

Wire placement

Nearly every pole shoe has a rectangular or quadratic coils shape. Consequently, the winding speeds of this winding technique are constantly changing and the wire tension control 

is expected to balance the speed variations effectively. The acceleration and deceleration of 

the wire guide and the different forces on the stator therefore require firm tool fittings and 

stability of the individual axes. This is a pre-requirement for the manufacturing of high 

quality windings. The wire processing on small stators is usually based on concentrated 

windings around the individual pole shoes. Therefore, it is significantly different to the 

processing of windings with insert technology, for which the winding can be inserted over 

multiple teeth. The placement does not necessarily follow from one stator tooth to the 

other. Different winding topologies are possible as well. 

The wire is bent after exiting the wire guide nozzle, since the wire guide nozzle moves 

past the placement contour sideways rather than with the front, like in other processes. 

This leads to a wire diversion of up to 90° and significantly strains the wire itself as well 

as the nozzle. It is often difficult to wind enamelled copper wires with larger gauges for 

small components with an orthocyclic scheme. The extreme bending of the wire before 

the placement is the reason for an undefined deformation geometry from the residual .

stresses. However, an ordered layer structure can be realised for large wire gauges with 

a precise manufacturing machine, using the properties of cylindrical bobbins. For better 

wire guidance, auxiliary tools may be used, as shown in Figure 3.62. Aside from guiding, 

they also pre-shape the wire. In accordance with the Bauschinger effect (Section 3.1.1), the 

wire can be bent in the opposite direction more easily.

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