Alternating current AC and direct current DC motors employ an insulated, current-carrying coil essential to their operation. The traditional method for motor rewinding involves removing the old coil, winding a new coil and varnishing. Old coils are removed by heating the stationary part of the motor stator in an oven. The stator is kept in the oven at temperature of degrees Fahrenheit for at least 10 hours or until the winding insulation turns to ash. New coils are traditionally wound by hand by a technician on a coil winding machine.

The technician controls the wire tension, layering and number of turns on the coil, although there is also a mechanical counter on the machine. The newly rewound coil is warmed in an oven, immersed in an epoxy varnish and baked in an oven at a temperature of degrees Fahrenheit for at least four hours. This procedure is known as dip and bake. A full-time writer sinceDavid Dunning is a professional freelancer specializing in creative non-fiction.

About the Author. Photo Credits. Copyright Leaf Group Ltd.During these challenging times, we guarantee we will work tirelessly to support you. We will continue to give you accurate and timely information throughout the crisis, and we will deliver on our mission — to help everyone in the world learn how to do anything — no matter what. Thank you to our community and to all of our readers who are working to aid others in this time of crisis, and to all of those who are making personal sacrifices for the good of their communities.

We will get through this together. Updated: August 19, Reader-Approved References. Given the sheer number of different motors and winding patterns, the rewinding process can vary greatly.

To rewind an electric motor, remove the motor's outer housing and use your hands to pull the armature out of the stator. Then, use a flat head screwdriver to pry open the tabs on the brush pads, and then cut through the wires and pull them out by hand.

Once you have the coil off of the armature and stator, wind a new wire of the same thickness and material into the armature.

Be sure to coil the wire the same number of times to ensure a proper fit for conductivity, and secure the coil with tabs before reassembling the motor. For tips on identifying the coil pattern and handling the motor during disassembly and assembly, scroll down! Did this summary help you? Yes No. Log in Facebook Loading Google Loading Civic Loading No account yet?

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coil winding process

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Learn why people trust wikiHow. This article was co-authored by our trained team of editors and researchers who validated it for accuracy and comprehensiveness.Electrical engineers perform coil winding to use coils as parts of electric circuits and for use in devices such as toroidal cores that are involved with magnetic fields and magnetic force.

The process

The shape and methods used to wind coils can let them be used for different purposes. The different ways of winding coil means you can wind coils for specific uses by taking into account voltage of the electrical current driven through the coils and the heat insulation properties of the devices themselves.

For electromagnets, materials that become magnetic in the presence of electric current flowing through wires, coils should be wound such that windings that are next to one another travel in opposite directions. This prevents the current that flows through them from canceling itself out between the layers of coils.

The ways engineers select the winding structure and methods of winding depend on the design choices such as the space available for winding when designing coils or the location of the final part of the coil that's meant to be wound. If you wanted to wind a coil by hand or do it as haphazardly as possible without respect to the optimal physics and mathematics underneath, this method is called wild winding or jumble winding. Jumble winding involves winding randomly without being conscientious of layer or filling in depths appropriately.

It's quick, easy, and gets the job done, but it doesn't change the inductance of the wound wire setup to produce an optimal voltage. It's used in small transformers, ignition coils, small electrical motors, and devices with small wire gauges. Machines that opt to wind coils helically spiral in every layer are helical winding machines.

As these machines create layers and layers of coil, they switch between directions, moving forward and backward or left-handed and right-handed, as engineers use to refer to those directions.

This only works for a small number of layers because when it reaches a certain limit, the structure becomes too tight to contain and jumble winding may result. Orthocyclic winding is the most optimal method to wind circular cross-sectional coils by placing the wires in the upper layers in the grooves of wires in the lower layers. These coils have good heat conduction and regularly distribute the field strength well among themselves.

Engineers take into account the efficiency of their coil winding processes by minimizing the materials and space required for coil winding. They do this to ensure they spend energy in an optimal manner. The electrical conductors used in coil winding occupy an area, and so does the winding used in the process. Engineers try to achieve as high fill factors as possible to make the coil winding process as efficient as it can be.

Though engineers generally calculate a theoretical fill factor of. This accounts for the angles of the spaces between the wires and layers of wires from the cross-sectional point of view.

The more densely packed wires are the higher the fill factor, as the coil winding machine can use the heat conductivity of the winding to prevent heat loss. Through this method, round wires in the upper layer of a coil winding machine should be packed such that they are in the grooves of the wires in the lower layer to ensure the packaging can encompass as many wires as possible.

The side view of the coils arranged in this manner show how different layers arrange themselves in the most efficient manner possible. Winding should run parallel to the winding flangesthe supports used to make sure coils wind as tight and efficiently as possible. Engineers should adjust the winding width to the number of turns per layer of the winding.This article describes the coil winding process for standard sensors and miniature medical sensors.

The process demands that the wire does not touch itself as it is wound around a core or other shape. First, the wire is isolated, or coated, with insulation and wound around a core or a pin. This arrangement creates electromagnetic induction. All copper coils used in the winding process contain wires that are insulated. Benatav uses a polyamide base material as insulation. However, several materials are available that are resistant to temperatures and breakdown voltages.

Most windings produce shaped coils. The main difference between coils is their shape and therefore their electrical values.

coil winding process

They can be wound into the following forms:. The inner and outer dimensions of the coil are crucial. The most crucial parameter for winding medical grade coils is the size. For example, to insert a coil into a vein, the coil must be smaller than 0. This requires highly specialized machinery that must be designed and built in-house.

how to make motor coil the motor stator coil winding process

Coils are made from insulated copper wire wound about a core or a pin. They can also be:. Benatav has plans to wind coil using wire that is thinner than 8 microns which will make it the thinnest coil in the world.

You cannot simply go and buy a machine capable of winding micro-coils. You need to engineer such machinery and create it from scratch. At Benatav, we call this in-house engineering. You use ultra-fine wires to manufacture inductive components and provide connectivity within miniature medical devices. This requires the interplay of several innovative technologies. These technologies are predicated on an array of methods for handling copper and other metal wires at any diameter, down to the finest serially manufactured size of 59 AWG 9 microns or 0.

As a result, only a handful of manufacturers in the world have the technical capability to serially manufacture coils that small. To create miniature coils requires a manufacturer uniquely qualified to wind ultra-fine wire and produce micro-coils. Benatav Advanced Winding Technologies is ready to help you with any questions or concerns about the process. Differences between Coils The main difference between coils is their shape and therefore their electrical values.

They can also be: coreless and self-bonded, i. Afterwards, the rectangular shape is removed, leaving a rectangular-shaped coil.If you have ever wanted to make a Tesla coil, but have been too daunted by the process of hand-winding the secondary, then this Instructable is for you.

In this instructable, I will show you how to wind a Tesla coil using an easily built machine, not a lathe, and how protect the windings. The video below will visually show you how to wind it. Lets get started! Did you use this instructable in your classroom? Add a Teacher Note to share how you incorporated it into your lesson.

To calculate the amount of wire you will use and how long the pipe is that will be used, you first need to know that you will need approximately turns. You can then plug in the variables into the equations below to find out how long your coil will be, how much wire you will need, how many turns you will have, wire gauge, and wire diameter. Many coils have different wire gauges and lengths. You can use these equations to find specifications for your coil.

To prepare the pipe, you will first need to cut it. Cut it to the length that you determined using the equations in step 2, and add about 2 inches. Then, use a wet paper towel to clean all of the dirt and pipe shavings off the coil. It is important that you keep this very clean. Impurities on the pipe can cause arc-over when this is used in a Tesla coil. Wait for the pipe to completely dry before continuing to the next step.

This is the most important part in winding the Tesla coil. The winding machine allows uniform windings at relatively high speeds. A Tesla coil winding machine can be built relatively quickly and easily. I built my winder using aluminium bars, rubber wheels, and a geared motor, but you can build it out of anything that works. This kind of tesla coil winder uses 4 wheels to rotate the piece of PVC pipe around its center axis. One wheel has a geared motor attached to it which lets the pipe be rotated automatically.

This can also be built using an upside-down RC car and something with wheels, but because every reader has different materials, I will leave building the winder up to the readers imagination. Ask questions in the comments for help with building the winder. To control the motor, I used a variable power supply. To wind the coil you will first need to take your pipe, and tape one end of the wire to one end of the pipe. This will hold it in place during winding, then tuck the wire inside the pipe.

Then, put the spool of wire vertically on a bolt so it will be able to rotate while the wire unwinds from it. After that, use an empty spool as a guide for putting the wire in the right place while using your thumb to compress the wire together.

This step is better explained through the above pictures and the video referenced in the intro. This step takes about an hour to perform because of the about of turns needed for a tesla coil.

One of the final steps in winding the secondary of a Tesla coil is protecting the windings. To protect the windings, use spray on lacquer.

Just spray the coil and give it at least 4 coats. This protects the windings from arc-over and dust. To test your Tesla coil, first you need to test the resistance of the windings. I used a multimeter to test resistance to make sure the wire had not broken.After a motor is rewound, the windings must be further insulated with resin or varnish. This insulation protects the windings from contamination, shorting electrically, and also make the windings more mechanically rigid.

Dip and Bake is a standard varnishing technique where the motor windings are dipped into a varnish tank and then set to cure in an oven. Typically, a new motor winding should be dipped twice double dip and bake to ensure the varnish fully covers the windings. Many repair shops do not allow the windings to cool once they are cured in the oven after the first dip and before the motor is dipped a second time.

Because the windings are still hot during the second dip, the varnish becomes more viscous and runs off the motor easily. This results in a less effective second dip of varnish.

Our varnish is Class N and Hermetic rated, meaning the varnished used can withstand higher temperatures and is fit for compressors respectively. Trickle Varnishing The winding is connected to a rotating table and electrical wires. Using electrical resistance, the winding gets heated while spinning.

Tesla Coil Winding: the Easy Way

Once at temperature, a tiny stream of varnish is trickled onto the winding head. The varnish follows the wire into the entirety of the slot, eliminating chances for partial discharge in random windings. Once fully saturated, the current is increased in the windings, resulting in the varnish curing while on the machine. This process is faster and better than the traditional dip and bake process because it cures on the machine — making it ideal for emergency repairs.

Vacuum Pressure Impregnation VPI utilizes a vacuum pressure tank filled with varnish to fully impregnate motor windings and insulation with resin or varnish. At Dreisilker, we preheat our windings, place the windings in our 10 ft. These cycles are all set to various times and capacitance is monitored to determine the resin or varnish fill is acceptable.

This process is typically used on medium voltage motors and form coil systems because traditional varnishing methods will not fully saturate the motor coils and their insulation tapes with varnish. The VPI method is the most time consuming process. Ultra-Sealed windings are completely impregnated and seals the coils with high molecular weight thermoset polymer resin. This allows for total protection against moisture, contaminants, and more efficient cooling. We recommend Ultra-Seal Windings for motors found in extreme environments, where contamination is likely.

Want to learn more about Ultra-Seal Windings? Your email address will not be published.

The Coil Winding Process

Before and after a stator being Ultra Sealed. Leave a Reply Want to join the discussion? Feel free to contribute! Leave a Reply Cancel reply Your email address will not be published.In electrical engineeringcoil winding is the manufacture of electromagnetic coils. Coils are used as components of circuits, and to provide the magnetic field of motors, transformers, and generators, and in the manufacture of loudspeakers and microphones.

The shape and dimensions of a winding are designed to fulfill the particular purpose. Parameters such as inductanceQ factorinsulation strength, and strength of the desired magnetic field greatly influence the design of coil windings.

Coil winding can be structured into several groups regarding the type and geometry of the wound coil. Mass production of electromagnetic coils relies on automated machinery. Efficient coils minimize the materials and volume required for a given purpose. The ratio of the area of electrical conductors, to the provided winding space is called "fill factor".

Since round wires will always have some gap, and wires also have some space required for insulation between turns and between layers, the fill factor is always smaller than one. To achieve higher fill factors, rectangular or flat wire can be used. Dense packing of wires reduces air space, and is said to have a high fill factor. This increases the efficiency of the electrical device and an improved heat conductivity of the winding. For best packing of round wires on a multi-layer winding, the wires in the upper layer are in the grooves of the lower layer for at least degrees of the coil circumference.

Also known as jumble windingwith this type of winding structure only poor fill factors can be achieved. The random wire placement leads to a wider distribution of resulting wire length on the coil body and consequently a wider range of electric coil resistances.

Despite its disadvantages, it is common in mass production. It is characterized by low demands for machinery and operator and can be wound with very high speeds. Wild windings are mostly applied in contactor - and relay coils, small transformers, Ignition coilssmall electrical motors, and generally devices with relatively small wire gauges up to 0.

The wires are placed helically in every layer. Owing to the direction of movement from layer to layer changing between right-hand and left-hand, the wires cross and locate themselves within the gap of the layer underneath. A wire guiding of the lower layer is not existent. If the number of layers exceeds a certain limit the structured cannot be maintained and a wild winding is created.

coil winding process

This can be prevented with the use of a separate layer insulation, which is needed anyway when the voltage difference between the layers exceeds the voltage strength of the copper wire insulation. This type of winding structure creates an optimal fill factor The windings of the upper layer need to be placed into the grooves provided by the lower layer. The best volume use is found when the winding is parallel to the coil flange for most of its circumference.

When the winding has been placed around the coil body it will meet with the previous positioned wire and needs to make a step with the size of the wire gauge. This movement is called winding step. The winding step can occupy an area of up to 60 degree of the coil circumference for round coil bobbins and takes one side of rectangular coil bobbins.

The area of the winding step is dependent on the wire gauge and coil bobbin geometry. If the winding step cannot be executed properly then the self-guiding ability of the wire is lost and a wild winding is produced. Overall, the first intruding wire mainly determines the location and quality of the winding step. It should be recognized that the wire needs to enter in a possibly flat angle into the winding space.


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