The brushless inner-wound stator is a core component of the motor structure, forming the motor's power system together with the rotor. It mainly consists of coils and an iron core, where the coils are wound around the core. When energized, the coils generate a rotating magnetic field that powers the motor and ensures stable operation.

As a key motor component, brushless inner-wound stators can be classified by process structure, winding method, and application scenarios. The terminal type, piercing type, and disc winding type stators represent different design and connection approaches, each with unique manufacturing features and practical advantages.

The terminal type stator achieves efficient and stable connection with external power sources or control systems through terminal design, ensuring reliable circuit operation and equipment stability. During manufacturing, a series of precise assembly processes and welding techniques guarantee high-quality production:

• The insertion of upper and lower insulation frames on the lead wire side effectively prevents the insulation frame from warping or creating gaps, ensuring electrical connection stability and reliability.
• The terminal type stator also offers distinct advantages in the winding process. An inner winding machine can automatically complete wire winding, hooking, slot changing, cutting, and unloading, and can flexibly select winding configurations (e.g., delta connection △, star connection Y, lower crossover wire) based on different application requirements to achieve optimal electrical performance.
• Resistance welding of copper wire to terminals enables efficient, low-deformation automated production while ensuring welding quality.

The key difference from the terminal type lies in the connection method between the terminal and the copper wire. The piercing type uses a piercing tool to break through the wire's insulation film, establishing direct conductivity between the terminal and the copper wire. This design eliminates the cumbersome step of stripping insulation and effectively prevents oxidation and cold solder joints. Additionally, flattening the core surface removes irregularities and burrs, improving the magnetic conductivity and energy efficiency of the stator's magnetic circuit. Thanks to its insulation stripping-free and oxidation-resistant advantages, the piercing type stator is highly favored in applications demanding high reliability.

The structural feature of the disc winding type stator is its unique coil arrangement. A compact coil structure is formed by winding copper wire onto the stator core in a special layout, giving the coils a disc-like appearance.

• In manufacturing, a high degree of automation is employed. The equipment can automatically insert coils into slots and precisely control critical parameters such as slot paper length, equipment precision, and core fit.
• The inner winding machine accurately executes key steps like wire winding, coil turns counting, winding speed, and tension control, ensuring coil quality. To enhance insulation, the insertion of phase-to-phase insulation paper and slot paper are crucial steps, typically requiring manual operation to ensure they are placed accurately and firmly between coils, effectively isolating the phases and preventing electrical faults.
• After coil winding, a series of post-processing steps is required, such as manually arranging wire harnesses and using a wire grinding machine to remove the insulation film from the neutral point copper wire. These steps are essential for improving overall coil performance and stability. Finally, performance testing verifies that the stator meets design specifications and operational requirements.

Achieving an efficient and stable connection for brushless inner-wound stators requires comprehensive optimization in manufacturing processes, connection methods, and equipment automation. The terminal type, piercing type, and disc winding type stators each have distinct characteristics in function, process features, and advantages, yet they all serve the ultimate goal of ensuring the brushless inner-wound stator delivers optimal performance and stability within the motor. In practical applications, the appropriate stator process type can be selected based on the motor's specific requirements and operating environment.