Stator Diagram

Stator Diagram

2024-10-16 by Cherry 

Introduction

In modern industrial production, die-casting machines, as 

an important metal forming equipment is widely used to 

produce various complex shapes and high-precision metal 

parts. It is used in many fields such as automobiles, 

electronics, aerospace, etc.

With the continuous advancement of technology, the requirements 

for key technologies and components in the field of die-casting

machines are getting higher and higher, and the concept and

application of "stator diagram" has gradually become the 

focus of attention in the industry. 

As a tool and method for motor design, stator diagrams can

effectively improve the performance and efficiency of 

die casting machines, help manufacturers optimize production

processes and improve product quality.

The stator diagram plays an indispensable role in the design,

manufacturing, operation, and maintenance of die-casting machines.

It is not just a drawing, but also a carrier containing rich

technical information and engineering wisdom. For practitioners

in the die-casting machine industry, being familiar with

and mastering the application of stator diagrams in the field of 

die casting machines are the key to improving work efficiency, 

ensuring product quality and promoting the development of the 

industry.

This article will deeply explore the various applications of 

stator diagram in the field of die-casting machines, as well 

as its impact and value, hoping to provide a useful reference 

and inspiration for professionals in related fields.

Overview of stator diagram

The stator diagram, originating from the field of motor design, 

refers to a technical diagram used to analyze the structure of 

the motor stator winding and its electromagnetic properties. 

It is an engineering drawing used to describe the stator 

structure and related parameters in detail.

As an important component in a motor or other rotating equipment,

the stator is responsible for generating an electromagnetic 

field, working with the rotor to drive the motor to rotate. 

The rationality and accuracy of its structure directly affect 

the performance and operating stability of the equipment. 

Through the stator diagram, the design of the stator winding,

the magnetic field distribution and the current flow can 

be effectively analyzed to optimize the performance of the 

motor.

In a die-casting machine, the stator is usually connected to 

the motor to provide power support for the operation of the 

die-casting machine. The stator diagram generally includes 

key information such as the stator's overall dimensions, core

structure, winding distribution, slot shape and size, and

wiring method. Through the stator diagram, engineers can 

clearly understand the design requirements and interrelationships

of the various parts of the stator, to carry out accurate 

manufacturing and assembly.

In the field of die-casting machines, the concept of stator 

diagram is not limited to traditional motor design, but can 

be widely used in motor-driven die-casting equipment. 

Through the design and optimization of the stator diagram, 

the power system, precision control, and efficiency of the 

die-casting machine have been significantly improved.

Working principle of die-casting machine and the role of 

stator

Working principle of die-casting machine

The working principle of the die-casting machine is to 

quickly inject molten metal liquid into the mold cavity 

under high pressure, so that it solidifies and forms under

pressure, thereby obtaining castings of the required 

shape and size.

It is mainly composed of a mold clamping mechanism, injection

mechanism, hydraulic system, electrical control system

and other parts. During the entire working process, 

various parts need to work together to accurately control

various parameters such as pressure, speed, temperature,

etc. to ensure the smooth progress of the die-casting 

process and the stability of the casting quality.

The role of stator in die-casting machine

The main role of the stator in the die-casting machine is 

to generate a rotating magnetic field through interaction 

with the rotor, drive the motor to operate, and then provide 

power for the injection mechanism and the clamping mechanism.

Its stable performance and precise power output are essential

for the normal operation of the die-casting machine.

If there is a problem with the stator, such as winding short 

circuit, core damage, etc., the motor may not work properly,

affecting the production efficiency and casting quality of

the die-casting machine, and even causing equipment shutdown,

causing economic losses to the company.

Therefore, the quality and performance of the stator play a 

pivotal role in the die-casting machine, and the stator diagram 

is an important basis for ensuring the quality and performance

of the stator.

Application of stator diagram in die-casting machine design

1. Structural design optimization

In the design stage of the die-casting machine, the stator

diagram provides engineers with detailed stator structure

information to help them optimize the reasonable structural

design.

Through the analysis and research of the core shape, slot

layout, winding method, etc. in the stator diagram, engineers

can optimize the stator structure as much as possible while 

meeting the motor performance requirements, improving its 

space utilization and heat dissipation performance.

For example, the reasonable design of the shape and size

of the core can reduce the magnetic circuit loss and 

improve the efficiency of the motor; optimize the layout

and the size of the slot can make the winding more evenly 

distributed, reduce the heating and resistance loss of the

winding, and also help to improve the power density of 

the motor.

In addition, the wiring method in the stator diagram will

also affect the electrical performance and control method

of the motor. Engineers need to select the appropriate 

wiring method according to the actual working requirements 

of the die-casting machine to ensure stable operation 

and precise control of the motor.

2. Parameter matching and calculation

Various parameters in the stator diagram, such as the 

number of winding turns, wire diameter, core material 

characteristics, etc., are important bases for motor 

parameter matching and calculation.

When designing a die-casting machine, engineers need to 

select and calculate the parameters of the motor based on

the working load, operating speed, pressure requirements

and other parameters of the die-casting machine, combined

with the relevant information in the stator diagram. 

Through accurate calculation and reasonable parameter matching,

it can be ensured that the motor can provide sufficient torque

and power during the working process of the die-casting machine

to meet the various working conditions of the die-casting machine.

At the same time, factors such as the motor's starting performance,

overload capacity, and speed regulation range need to be considered

to ensure that the die-casting machine can operate stably under

different working conditions.

For example, when calculating the number of turns and wire

diameter of the winding, it is necessary to consider the

rated voltage, current, power factor, and other parameters

of the motor, as well as the heat dissipation conditions

and insulation requirements of the winding. Through reasonable 

calculation and selection, it is ensured that the winding can

withstand the impact of the working current and will not be

damaged by overheating during operation.

3. Collaborative design and system integration

The die-casting machine is a complex mechatronics system.

The stator needs to be collaboratively designed and the system 

integrated with other components as a key component.

The stator diagram plays an important bridging role in this 

process. It transmits the design requirements and parameter 

information of the stator to the designers of other related 

components, so that the entire die-casting machine system can

achieve seamless docking and efficient collaborative work.

For example, when designing a hydraulic system, it is 

necessary to consider the power and speed of the motor to

determine the displacement and working pressure of the 

oil pump; when designing an electrical control system, it

is necessary to select appropriate controllers and sensors 

according to the winding connection method of the stator 

and the control requirements of the motor to achieve precise

control and monitoring of the motor.

Through the collaborative effect of the stator diagram, 

problems such as parameter mismatch and interface inconsistency

between various components can be avoided during the design

process, and the overall performance and reliability of 

the die-casting machine system can be improved.

Application of stator diagram in die-casting machine 

manufacturing

1. Processing process guidance

The stator diagram provides a detailed processing process

guidance for the manufacturing process of the die-casting

machine stator. When manufacturing the stator core, it 

is necessary to select appropriate processing methods and 

process parameters, such as stamping, cutting, grinding, 

etc., according to the core shape and size requirements in 

the stator diagram.

At the same time, it is also necessary to strictly control

the processing accuracy and surface quality of the core

to ensure the magnetic properties and assembly accuracy 

of the core. During the winding production process, the 

stator diagram specifies the number of turns, wire diameter,

winding method and other process requirements of the 

winding. 

Workers need to perform precise winding and wiring operations 

according to the requirements of the drawings to ensure that

the electrical performance and insulation performance of

the winding meets the standards.

In addition, the stator diagram will also provide detailed 

instructions for the assembly process of the stator, including 

the assembly sequence, tightening torque, matching tolerance

and other requirements of each component. Workers must 

strictly follow the requirements of the drawings during 

the assembly process to ensure the overall quality and performance

of the stator.

2. Improve the driving force of the die-casting machine

During operation, the die-casting machine needs to inject 

molten metal into the mold. The power of the drive system 

directly determines the efficiency of the die-casting machine

and the quality of the finished product.

Traditional die-casting machines are mostly driven by hydraulic

systems, while modern electric die-casting machines are 

driven by electric motors. The optimized design of the stator

diagram can significantly improve the driving force of the 

motor.

By analyzing the magnetic field distribution and current 

flow path of the stator winding, engineers can design more

efficient motors, thereby improving the output power and 

production efficiency of the die-casting machine.

3. Enhance the precision control of the die-casting machine

During the die-casting machine's molding process, the die-casting 

force's control accuracy and injection speed are crucial. 

The application of the stator diagram makes the motor respond 

faster and the control more accurately.

In the electric system of modern die-casting machines, the 

stator diagram not only optimizes the magnetic field distribution

of the motor, but also can reduce electromagnetic interference

and fluctuations by accurately controlling the current, 

thereby achieving more stable die-casting force control. 

This is especially important for die-casting parts with complex

shapes and high precision.

4. Improve the energy efficiency of the die-casting machine

Energy efficiency is one of the important indicators that 

die-casting machine manufacturers pay attention to. The 

application of stator diagrams helps to optimize the design

of motors and reduce energy consumption.

During the operation of the motor, the uneven distribution 

of current and magnetic field in the winding will lead to 

energy loss. Through the analysis of the stator diagram, a

uniform magnetic field distribution can be accurately 

designed to reduce the energy loss of the motor and improve

the overall energy utilization rate. This not only helps

to reduce production costs but also conforms to the current

trend of green manufacturing.

5. Extend the service life of equipment

Die-casting machines usually operate under high-intensity 

and high load, which challenges the durability of the equipment.

The optimized design of the stator diagram can not only 

improve the efficiency of the motor, but also reduce the 

heating and electromagnetic interference of the winding, 

reduce mechanical wear, and thus extend the service life 

of the die-casting machine.

The reasonable design of the stator enables the motor to 

work stably under long-term high load, reduce the failure 

rate and maintenance cost, and improve the overall reliability

of the equipment.

6. Quality inspection and control

The stator diagram is an important basis for the quality

inspection of the die-casting machine stator. In the 

stator manufacturing process, quality inspection is required 

after each process is completed to ensure that the product

quality meets the design requirements of the stator diagram.

Quality inspectors can use corresponding measuring tools 

and testing equipment to inspect the stator according to 

the dimensional tolerance, shape tolerance, surface roughness

and other requirements in the stator drawing. For example, 

use calipers, micrometers, and other measuring tools to 

measure the stator's external dimensions, use a roughness 

meter to detect the roughness of the core surface, and use 

an insulation resistance tester to test the insulation 

performance of the winding.

For products that do not meet the requirements of the 

drawings, they need to be reworked or scrapped in time 

to prevent unqualified products from flowing into the 

next process, thereby ensuring the overall quality and 

reliability of the stator.

At the same time, the stator drawing can also provide a 

reference for quality control. By monitoring and recording

key process parameters in the stator manufacturing process, 

such as stamping pressure, winding tension, welding temperature, 

etc., problems that arise in the manufacturing process can 

be discovered and solved promptly to ensure the stability and

consistency of product quality.

Application of stator drawings in die-casting

machine operation and maintenance

1. Fault diagnosis and troubleshooting

During the operation of the die-casting machine, the stator

may have various faults, such as winding short circuits,

open circuit, grounding, core overheating, looseness, etc.

The stator diagram plays an important guiding role in fault

diagnosis and troubleshooting.

When a die-casting machine fails, maintenance personnel 

can refer to the stator diagram to understand the structure

and electrical connection of the stator, and combine the 

actual fault phenomenon to preliminarily determine the type

and location of the fault.

For example, if the die-casting machine motor cannot start,

maintenance personnel can check whether the winding wiring 

is correct and whether there is a break or short circuit 

according to the stator diagram; if the motor is abnormally

hot during operation, maintenance personnel can analyze 

whether the heat dissipation structure of the iron core is 

reasonable through the stator diagram, and whether there 

are problems such as loose iron cores or short circuits.

After determining the fault location, maintenance personnel 

can further perform maintenance operations according to the 

stator diagram, such as replacing damaged windings, repairing

iron cores, etc., to quickly troubleshoot and restore the normal

operation of the die-casting machine.

2. Maintenance plan formulation

The stator diagram can also provide a basis for the formulation

of the maintenance plan for the die-casting machine. According

to the information such as the service life, maintenance 

cycle, and maintenance requirements of the stator specified 

in the stator diagram, equipment management personnel can 

formulate a reasonable maintenance plan and regularly inspect,

maintain and maintain the stator.

For example, the insulation resistance test of the stator 

winding is carried out according to the prescribed maintenance

cycle to check whether the winding is aging, damaged, etc.;

the iron core is cleaned and tightened to check whether the

iron core is loose, deformed, etc.; the stator terminal is 

checked and tightened to ensure that the wiring is firm and 

reliable.

Through regular maintenance, potential problems of the 

stator can be discovered and dealt with in time, the service

life of the stator can be extended, the operating reliability

and stability of the die-casting machine can be improved,

and the equipment failure rate and maintenance cost can be

reduced.

3. Technical transformation and upgrading

With the continuous advancement of science and technology 

and the development of the die-casting machine industry, 

enterprises may need to carry out technical transformation

and upgrading existing die-casting machines to improve

the performance and production efficiency of the equipment.

The stator diagram also has an important reference value 

in this process. Through the analysis and research of 

the original stator diagram, engineers can understand 

the structure and performance characteristics of the existing

stator, and optimize the design and transformation of the

stator in combination with new technical requirements and 

process methods.

For example, adopting new core materials and winding technology 

to improve the magnetic and electrical properties of the 

stator; improve the heat dissipation structure of the stator

to enhance its heat dissipation capacity and reduce the 

operating temperature of the motor; increase the protection

level of the stator to improve its working reliability 

in harsh environments, etc. 

When carrying out technical transformation and upgrading,

it is necessary to ensure that the new stator design matches 

other components of the die-casting machine and can meet the

overall performance requirements of the equipment, and the 

stator diagram is an important tool to achieve this goal.

Technical advantages of stator diagram

As a graphical tool in motor design, the stator diagram 

can not only help designers optimize motor performance, 

but also has other significant technical advantages:

1. Strong intuitiveness: The stator diagram can display the stator

winding and magnetic field distribution, helping designers to

quickly find deficiencies in the design and optimize the 

design scheme.

2. Improve design efficiency: The stator diagram can shorten 

the time of motor design, make the design process more efficient,

and help manufacturers launch new die-casting machines faster.

3. Wide adaptability: The stator diagram is not only suitable 

for the design of electric systems in die-casting machines,

but can also be applied to the design of motors for other 

industrial equipment, with wide adaptability.

4. Improve product competitiveness: The electric system of the

die-casting machine optimized by the stator diagram can 

not only improve production efficiency but also effectively

reduce energy consumption and equipment maintenance costs,

making the product have more advantages in market competition.

Challenges and coping strategies in the application

of stator diagrams

1. Drawing accuracy and update

In practical applications, the accuracy and timeliness of 

the stator diagram is an important issue. If the drawing 

is wrong or inconsistent with the actual situation, it may

lead to increased scrap rates in the manufacturing process,

difficulties in equipment installation and commissioning, 

and operational failures. 

To ensure the accuracy of the stator diagram, designers need

to strictly follow the relevant standards and specifications

when drawing the drawings, and carefully review and proofread

the drawings.

At the same time, during the design, manufacturing, and use

of the die-casting machine, if the stator diagram is found 

to have problems or needs to be modified, it should be updated

and improved in time to ensure that the drawings are consistent 

with the actual situation. In addition, digital technologies 

such as computer-aided design (CAD) and computer-aided manufacturing

(CAM) can be used to manage and maintain the stator diagram

to improve the accuracy and traceability of the drawings.

2. Technical staff's understanding and application ability

As a professional engineering drawing, the stator diagram 

requires relevant technical staff to have certain professional

knowledge and skills to correctly understand and apply it. 

However, in actual work, due to the uneven level of technical 

staff, there may be incomplete understanding or improper 

application of stator diagrams. 

To improve the technical staff's ability to understand and 

apply drawings, enterprises can strengthen the training and 

education of technical staff, regularly organizing relevant 

technical training courses and learning exchange activities, 

so that technical staff can have an in-depth understanding of 

the stator diagram drawing specifications, marking methods, 

technical requirements and other contents, and master the 

application methods and skills of stator diagrams in die-casting

machine design, manufacturing, operation, and maintenance. 

At the same time, enterprises can also encourage technical staff 

to continuously accumulate experience in actual work, improve their

ability to solve practical problems, and ensure that stator 

diagrams can be correctly and effectively applied.

3. Cross-departmental collaboration and communication

The application of stator diagrams involves multiple departments 

such as die-casting machine design, manufacturing, quality inspection,

and equipment maintenance, which requires close collaboration and

communication between departments. 

However, in actual work, due to the different division of responsibilities

and work processes between departments, there may be problems such

as poor communication and inadequate collaboration, which affects 

the application effect of stator diagrams. 

To strengthen cross-departmental collaboration and communication,

enterprises can establish a sound project management mechanism and 

communication and coordination mechanism, clarify the responsibilities

and tasks of each department in the application of stator diagrams, 

and strengthen information sharing and communication between departments.

For example, during the design phase of a die-casting machine project,

personnel from the design, manufacturing, quality, and other departments

can be organized to jointly participate in the review and discussion 

of the stator diagram, and timely discover and solve problems in the

drawings.

During the manufacturing process, strengthen communication between

the design department and the manufacturing department, a timely 

feedback on the actual situation in the manufacturing process, and make 

necessary adjustments and optimizations to the stator diagram.

During the equipment operation and maintenance phase, establish a communication

channel between equipment maintenance personnel and designers, and obtain

updated information and technical support for the stator diagram promptly 

to ensure the normal operation and maintenance of the equipment.

Actual cases of stator diagrams in the field of 

die-casting machines

In recent years, many die-casting machine manufacturers have applied 

stator diagram-optimized motor designs in their products, significantly

improving the performance of the equipment. For example, a world-leading

die-casting machine manufacturer applied stator diagram technology in its 

new generation of electric die-casting machines, optimized the stator winding

structure of the motor increased the output power of the die-casting 

machine by 20%, reduced energy consumption by 15%, and greatly improved 

the accuracy of the injection speed. 

This technological innovation helped the company win more market share

and gain a firm foothold in the high-end die-casting machine market.

Future development trend of stator diagram in die-casting

machine field

As the requirements of industrial manufacturing for efficiency, precision

and energy utilization continues to increase, the application prospects 

of stator diagrams in the field of die-casting machines are broad. In the 

future, this technology is expected to make breakthroughs in the following

aspects:

1. Intelligent and automated development: The design of future die-casting 

machines will be more intelligent, and stator diagram technology can be 

combined with intelligent manufacturing systems to automatically optimize 

motor design, further improving the production efficiency and equipment 

intelligence level of die-casting machines.

2. Application of new materials: With the development of new conductive 

materials and magnetic materials, stator diagram technology will further

optimize the winding structure and magnetic field distribution of motors,

improve motor performance, especially in extreme environments such as 

high temperature and high pressure.

3. Application of energy die-casting machines: With the development of new 

energy and renewable energy technologies, stator diagram technology will 

play a greater role in the electric drive system of die-casting machines.

New energy die-casting machines will adopt more efficient motor designs 

to achieve lower energy consumption and higher production efficiency, 

helping the manufacturing industry to move towards green and sustainable 

development.

Conclusion

As a key technology in motor design, stator diagram is bringing 

new technological innovations in the field of die-casting machines.

Through the optimized design of the stator diagram, the driving 

force, precision control, energy efficiency, and equipment life of 

the die-casting machine has been significantly improved, providing

a more efficient and reliable solution for modern industrial production.

The application of stator diagrams in the field of die-casting machines

runs through the entire product life cycle, from design, and 

manufacturing to operation and maintenance, and plays a vital role.

It is not only an important basis for the design and manufacturing

of die-casting machine stators, but also a key factor in ensuring 

the stable performance and reliable operation of die-casting machines.

Through the reasonable application of stator diagrams, the structural

design of die-casting machines can be optimized, and manufacturing 

accuracy and quality can be improved, the failure rate can be reduced,

and the service life of equipment can be extended, thereby providing

strong support for enterprises to improve production efficiency, 

reduce production costs, and enhance market competitiveness.

However, there are also some challenges in the application of stator 

diagrams, such as drawing accuracy and updating, technical personnel's 

understanding and application ability, cross-departmental collaboration

and communication, etc. 

In response to these problems, enterprises need to adopt corresponding

response strategies, strengthen drawing management, improve the quality

of technical personnel, and optimize cross-departmental collaboration 

mechanisms to ensure that stator diagrams can be correctly and effectively 

applied. 

With the continuous development and progress of die-casting machine 

technology, the application of stator diagrams will continue to deepen

and expand, bringing more opportunities and challenges to the development

of the die-casting machine industry.

As practitioners in the die-casting machine industry, we should fully realize

the importance of stator diagrams, continue to learn and master relevant 

knowledge and skills, actively respond to various challenges and contribute 

to the high-quality development of the die-casting machine industry.

With the continuous advancement of technology, the application of stator 

diagrams in the field of die-casting machines will be further expanded and

become an important means to enhance the performance and market competitiveness 

of die-casting machines. In the future, we can foresee that stator diagrams 

will play a more important role in the electrification, intelligence, and green 

manufacturing development of die-casting machines, injecting new impetus into 

the technological innovation of the manufacturing industry.

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Contact us to discuss the details of your project and we'll 

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