Winding an electric motor's stator

[damzi]

TL;DR Summary

Hi all. I am up to wind the stator of a newly designed dc motor. It’s a 3 phase and each slot need to get winded with 8 strands of AWG 22 wire for 7 turns.

I need to get an opinion from you experts for a pattern / way to do the winding.
Everytime I tried it seems like there is no space to wind around the slot. I tried winding single wire by wire.
Please help. The winding need to be done as 8 strands in hand and 7 turns per slot.

 

[jrmichler]

Everytime I tried it seems like there is no space to wind around the slot.

Your description is unclear. Are you trying to say that you cannot get the required number of turns into the slot because there is not enough room in the slot? Or are you having trouble with the end turns? A photo showing your best attempt would be very helpful. Include a detailed description with the photo.

If you have trouble fitting all the wires into the slot, we need more information. An accurate diagram showing the slot dimensions, the exact thickness of the slot insulation, and the exact diameter of the wire you are using. Note the wire diameters shown in tables usually are the copper diameter. We need the diameter with the insulation. Have you calculated the slot fill? What assumptions did you make?

The photo looks a lot more like a rotor than a stator.

 

[Ivan Nikiforov]

TL;DR Summary: Hi all. I am up to wind the stator of a newly designed dc motor. It’s a 3 phase and each slot need to get winded with 8 strands of AWG 22 wire for 7 turns.

I need to get an opinion from you experts for a pattern / way to do the winding.
Everytime I tried it seems like there is no space to wind around the slot. I tried winding single wire by wire.
Please help. The winding need to be done as 8 strands in hand and 7 turns per slot.

View attachment 354963

View attachment 354964

During the manufacture of the winding, the wire is sealed in the grooves using a wooden or plastic blade. You can try to reduce the thickness of the insulating shell (white in the photo). In any case, your winding should be tight so that the wires in the slots cannot move freely under the influence of electromagnetic and mechanical forces. To do this, I additionally impregnate the winding with varnish