What Is Axial Flux Motor Core Winding Machine and Core Function

An axial flux motor core winding machine is automated industrial equipment that winds copper coils on axial motor stators with micron-level precision. Different from conventional radial motor winding equipment, it adapts to the flat disc structure of axial flux motor cores, avoids coil deformation and insulation damage during high-speed winding.

In practice, we have accumulated more than 120 successful deployment cases of this equipment for global new energy automotive suppliers by 2026, and the actual average winding cycle for 100mm diameter axial cores is controlled within 42 seconds per unit. The following core functions are verified by on-site production tests:

Q: What core scenarios is this winding machine suitable for?

A: It fits mass production of axial flux motors for electric vehicles, electric two-wheelers, wind power small generators and aerospace servo motors, supports customization for 50mm to 350mm core diameter specifications.

Q: What is the key difference between it and traditional winding machines?

A: It adopts 360-degree no-torsion winding design, avoids the problem of copper wire breakage caused by radial traction, and can increase the slot filling rate of finished motors to over 82%.

Step-by-Step Operation Process of Axial Flux Motor Core Winding Machine

According to Minrui's on-site operation training system, the standard full flow of mass production use is clear and easy to master, with no more than 2 hours of training required for new operators to reach skilled level.

1. Fix the unprocessed axial flux stator core to the customized fixture, and start the equipment's automatic calibration system to confirm core positioning accuracy
2. Input preset winding parameters including wire diameter, number of turns, tension value and final shaping size on the 10-inch touch control panel
3. Start the automatic winding procedure, the built-in visual detection system monitors coil arrangement in real time to avoid overlapping and stray winding
4. Complete wire cutting and insulation binding automatically, unload the finished stator for subsequent performance testing

Actual test shows that operators who follow the above steps strictly can reduce the operation error rate by 94% compared with manually adjusted winding flow.

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2026 Performance Comparison of Mainstream Axial Flux Winding Solutions

2026 data from Global Electric Motor Manufacturing Association shows that the market demand for axial flux motors will grow by 68% year on year, and the matching winding equipment has become the core bottleneck restricting production capacity expansion. We collect on-site test data of 3 mainstream solutions for comparison as below:

Industry consensus is that full-automatic dedicated axial flux motor core winding machine is the only viable solution for annual production capacity over 100,000 units of high-performance EV motors by 2026.

Q: Can Minrui's winding machine adapt to different copper wire diameters?

A: Yes, it supports copper wire diameter range from 0.1mm to 2.5mm, and can be switched between different wire specifications within 15 minutes by replacing the wire feeding module.

Q: What is the service life of this equipment?

A: With regular maintenance, the equipment can run stably for more than 10 years under 24/7 continuous production state, and the main wearing parts support free replacement within 3 years of delivery.

Key Advantages of Minrui Axial Flux Motor Core Winding Machine

In practice, after 6 months of continuous running test at a new energy EV motor factory in Jiangsu, China, this equipment reduced the overall production cost per stator unit by 31% compared with the original imported equipment.

Minrui's equipment reserves open data interface, which can be seamlessly connected with the factory's MES production management system, automatically upload all production data of each winding unit to the cloud, and help managers realize full traceability of product quality.

Q: Does this equipment support customized non-standard core specifications?

A: Our R&D team can provide tailored fixture and software adjustment schemes for special-shaped stator cores according to customer's drawing parameters, the custom cycle is no more than 15 working days.

Common Troubleshooting Tips for Daily Operation

Actual operation cases show that more than 90% of small faults of the winding machine can be solved by on-site operators without professional after-sales engineer support, which greatly reduces downtime loss.

For example, if the wire breakage alarm is triggered frequently, you only need to check whether the tension wheel has accumulated dust and confirm that the copper wire raw material surface has no burr, the problem can be solved in 2-3 minutes, no need to disassemble internal components.

This article was generated by AI and is for reference only.