BLDC Motor Stator Needle Winding Machine 60RPM Parallel Wires To 600RPM Thin Wire

This needle winding can wind both inslot stator and outrunner stator,

with four axis Yaskawa Servo Motor ,winder is flexible in movement,

the actions winding,crossing, wrap, and slotting, cutting are done automatically

The needle winding speed is related to wire size, stator size and stack height,

Max. 500RPM when the wire is 0.1mm, stator is small and stack height is small,

Min 60RPM when the wire is big, stator size and stack height is big,

Winding machine Advantages

1. By moving up and down the nozzle and rotating the stator core, it can be wound in any track.

Therefore, by changing the computer winding procedure,

the windings can be adjusted to stators with different core stack height and different slot no.

2. Any operation abnormality and fault status are prompted to operate and maintain in human-machine
dialogue mode.
3. The number of stitching feet can be set arbitrarily by thread, and the specified 360 degree position

can be stopped, which makes the threading simple,convenient and shortens the overall production time

4. When winding, the number of coils in each layer can be flexibly changed to achieve the
winding arraying mode of different stator types.

5. Product programming is simple and convenient, with unique dedicated software,
unlimited upload and download storage. Easy to master with simple training.
6. Since the in-line slotting action is performed by the high-performance control system and
the Yaskawa servo motor, the stability of the position of the in-line enameled wire
is ensured and the time is shortened.
7. Each unit has been standardized, easy to replace and easy to disassemble.

8. All the toolings are very easy to be changed within 1 minutes expect

Please click below video to watch machine working

When choosing a needle winding machine, the most important thing is usually:

Whether it can produce stable, damage-free, high slot-fill winding consistently.

Because needle winding is mainly used for:

• BLDC stators
• EV motors
• drone motors
• servo motors
• appliance motors

where winding quality directly affects:

• efficiency
• torque
• heat generation
• reliability

The key factors are:

1. Winding Accuracy (Most Critical)

Needle winding requires extremely accurate wire positioning.

Important points:

• turn count accuracy
• layer consistency
• repeatable needle motion
• accurate indexing between teeth

Poor accuracy causes:

• uneven back EMF
• imbalance
• vibration
• lower efficiency

Look for:

• servo-controlled axes
• high repeatability
• precision interpolation control

2. Wire Protection

Very important.

During needle winding, the wire experiences:

• bending
• tension
• friction
• acceleration

If the machine damages enamel:

• short circuits occur
• insulation reliability drops

Important features:

• smooth needle surface
• ceramic guides
• optimized needle path
• stable tension control

Especially critical for:

• fine wire
• high-speed winding
• hairpin-dense stators

3. Slot Fill Capability

One major advantage of needle winding is:

High slot fill factor

Better slot fill means:

• more copper
• higher torque density
• lower copper loss

Machine selection should consider:

• smallest slot opening
• tooth geometry
• achievable copper fill ratio

Some motors become impossible to wind if:

• needle size is too large

4. Needle Design

The needle itself is extremely important.

Needle dimensions affect:

• accessible slot size
• winding speed
• wire stress

Key parameters:

• needle outer diameter
• inner diameter
• curvature
• material hardness

Small needle:

• better access
• lower productivity

Large needle:

• faster winding
• poorer accessibility

5. Number of Axes

Modern needle winders often use:

• 3-axis
• 5-axis
• 6-axis
• multi-servo systems

More axes allow:

• complex winding paths
• difficult stator geometries
• higher flexibility

Especially important for:

• concentrated winding BLDC motors

6. Tension Control

Extremely important.

Bad tension causes:

• loose winding
• wire overlap
• inconsistent resistance
• enamel damage

Best systems use:

• electronic tensioners
• closed-loop tension feedback

7. Production Speed

Important for mass production.

Needle winding speed depends on:

• needle acceleration
• indexing speed
• wire feeding system
• control algorithm

But:

excessive speed may reduce quality.

Good manufacturers optimize:

• motion trajectory
• acceleration curve
• vibration suppression

8. Stator Compatibility

Machine must match:

• slot number
• stator OD/ID
• stack length
• slot opening
• tooth shape

Especially important for:

• segmented stators
• internal stator winding
• outrunner motors

9. Automation Capability

Modern systems may include:

• auto loading
• wire cutting
• terminal handling
• welding
• vision inspection
• automatic parameter switching

Important for:

• reducing labor
• consistency

10. Ability to Wind Difficult Motors

Very important in advanced motors.

Examples:

• drone motors
• humanoid robot motors
• axial flux motors
• hairpin alternatives
• high-pole outrunners

• Some machines cannot handle:

• narrow slots
• deep slots
• high tooth count

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  11. Motion Stability

  At high speed:

• vibration becomes critical

• Poor machine rigidity causes:

• wire jumping
• inconsistent layering
• needle collision

• A rigid machine frame matters a lot.

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  12. Software & Programming

  Modern winding machines rely heavily on software.

  Good software allows:

• trajectory optimization
• recipe storage
• simulation
• quick changeover

• Bad software causes:

• difficult debugging
• long setup time

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  13. Maintenance & Reliability

  Important for factory uptime.

  Check:

• servo brand
• PLC system
• spare parts
• maintenance access
• lubrication design

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  14. Process Integration

  Needle winding often connects with:

• insulation insertion
• epoxy dispensing
• testing
• magnet insertion
• balancing

• Integrated production lines improve consistency.

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  15. Most Important for Different Industries

  Industry	Most Important Factor
  Drone motor	speed + low wire damage
  EV motor	slot fill + automation
  Humanoid robot	precision + torque density
  Appliance motor	cost + stability
  Medical motor	consistency + cleanliness