Disassemble the old coil to obtain the size data of the original coil, including circumference, height (thickness), width and groove shape.
Design and manufacture of winding die;
According to the measured data, choose the appropriate material (such as wood, plastic or metal) to make the winding die.
According to the shape and size of the coil slot, the basic shape of the die is cut out.
If the coil has a special shape (such as trapezoid or rectangle), make sure that the mold is designed according to the gradual size of the coil.
Calibrate the position of turns on the die to control the position and tightness of each turn in the winding process.
Fixation and insulation treatment:
In order to prevent short circuit caused by direct contact between the coil and the mold, insulating materials such as electrical paper or polyester film can be wrapped on the surface of the mold. Rewinding coil process:
Prepare enameled wire:
According to the parameters of the motor, choose the enameled wire with appropriate specifications to ensure that the length is enough to complete the rewinding of all coils.
Start winding:
Fix one end of the enameled wire at the initial position of the mold.
Enamelled wires are evenly wound along the outline of the mold, so that the tightness between coils in each turn is consistent and the paint layer will not be crushed.
After reaching the predetermined number of turns, fix the thread end and take out the wound coil.
Embedded in the motor slot:
The wound coil should be accurately embedded in the stator slot of the motor to maintain the correct phase relationship with other coils.
Welding and connection:
Ensure that the head lead and tail lead of each coil are properly connected and firmly connected to the motor terminal by welding or other means.
Precautions:
Pay attention to electricity safety during the whole process to avoid electric shock.
All dimensions must be accurate, otherwise the performance and efficiency of the motor may be affected.
The working environment should be kept dry and clean to prevent dust and impurities from entering the coil.
Ensure good insulation between enameled wires to prevent short circuit.
For a three-phase motor, the angular arrangement between coils of each phase should be strictly in accordance with the motor pole number and design requirements.
If the coil is too tight, it will increase the resistance and cause heat, and if it is too loose, it may cause vibration and noise.