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Motor Winding Technique  Rate Topic 
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 Posted: Sun Sep 12th, 2021 12:14 pm
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Mark Olson
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Do any of you motor winders have any tips, tricks or hints for inserting the coils in the stator slots?


I am rewinding an unobtainable Energy Recovery Ventilator motor for a friend. It is a 3.3" diameter motor, and the difficulty of getting the coils in the slots seems to increase exponentially with the inverse of the square of the diameter of the motor.


On this motor, the start winding lays in first; it is #30 awg and it was difficult to fit in. I was thinking that the run winding would be easier because it is thicker, #25 awg. I was wrong.
Any suggestions will be greatly appreciated! :pissed

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 Posted: Mon Sep 13th, 2021 01:21 pm
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Jim Kovar
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Mark Olson wrote: ...the difficulty of getting the coils in the slots seems to increase exponentially with the inverse of the square of the diameter of the motor.

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 Posted: Mon Sep 13th, 2021 08:02 pm
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Mark Olson
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Jim Kovar wrote: Mark Olson wrote: ...the difficulty of getting the coils in the slots seems to increase exponentially with the inverse of the square of the diameter of the motor.

Jim, I tried to write a proof, or at least a theorem, but there seems to be an error... if it were the inverse of the square of the radius squared (square root), then dividing by pi... I don't know... I seem to be going in circles here!

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 Posted: Mon Sep 13th, 2021 08:15 pm
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Jim Kovar
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Mark Olson wrote: ...I tried to write a proof, or at least a theorem, but there seems to be an error...
Ah!,...   but


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 Posted: Mon Sep 13th, 2021 08:19 pm
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Mark Olson
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It's hypotenuse, not hippotumoose!

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 Posted: Sat Sep 18th, 2021 02:53 pm
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Mark Olson
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Well, I answered my own question. These later 3.3 inch motors were apparently machine wound directly on the stator for optimum slot fill factor, and they used kapton 2.5 mil slot insulation.  I wound the coils on a coil winder and inserted them into the slots, which were insulated with 0.010 fish paper insulation. This combination does not lend itself to a quick and easy rewind. It can be done, but it takes lots of time, patience and bamboo sticks to push the coils into the slots. Did I mention it takes time? Here is the finished winding, running a current through it to bake the varnish.






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 Posted: Sat Sep 18th, 2021 08:29 pm
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Stan Adams
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One thing for sure, you have much more patience than I do!

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