3.

EXPERIENCE OF MOTOR WINDING

3.1 Motor Winding Shop

The duties of motor winding shop at JIP are, rewind defect motors, transformers in Loadstar. I could rewind a
three phase motor.

3.2 Motor Rewinding Procedure

1. Calculated the number of turns of a coil and no of slots.

No of turns= 267 No of slots= 24
2. Removed the old coils without any damage to the stator and cleaned the surface between slots.
3. Removed the insulation code of a coil and measured the diameter using the micrometer. It can be found
the diameter, rated current and SWG from a chart.

SWG Diameter (Inch) Diameter (mm) Max. current (A)

30 0.018 0.315 241.61
Table 3.1 SWG, Diameter, Rated Currenr Chart

4. Set the insulation papers into the slots. Used Milinax insulation material.

Figure 3.1 Set of Insulation Papers

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5. Make the former according to the correct lengths.

Connect hole
for hand shake
52mm
electric wind
thread
machine.

68 mm

Figure 3.2 Former

6. Winding the coil in above former.

7. Set the winding coil into correct slots.
8. When put the coils in to the slots, use instruments that made from wood, rubber or plastic. Put coils into
the slots carefully with not damaging to the Enameled winding wire or to the insulation.
9. Set the insulation papers over the winding.

Figure 3.3 Stator with coil sets

10. Inserted lethoride insulation papers to separate two coils.

11. Binded the coil using twin thread. (Nylon)

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12. Connected the coil beginnings and endings according to the following winding connection system using
sleeves.

A2

C1

B2

A1 B1
C2
Figure 3.4 Winding connection

13. Bind the other side.

14. Measured the winding continuity using insulation megger.
15. Fixed the rotor with stator.
16. Gave the supply to the three endings and measured the current in each phase using a clip on meter
(clamp on meter).
(i)0.5 A (ii)0.5A (iii)o.5A
17. The motor was kept in oven in 1.5 hrs until the temperature is 1800c.
18. Poured the shellac(insulation varnish) to the winding to prevent the winding from any damage and for
the insulation purpose.
19. The motor was again kept in oven until the temperature is 1800c.
20. Fixed the rotor to the stator and checked the current.
(i) 0.5A (ii) 0.5A (iii) 0.5A

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3.3 Insulation Papers

Insulation is very important thing in motor winding. In this we use insulation papers to protect the coils
touch with each coil sets and steel of the body of the motor. There are several types of insulation papers
with several gauges. We selected these papers according to the power supply of the motor. If the
current supply is high, the resistance can be high and insulation paper will be burn. So we must very
careful about selecting insulation papers.

Types of insulation papers; Milinax

Letharoid

Nomax

3.4 Connection Methods

In 3-phase motor there are two connection methods.

Figure 3.5- Connection Methods

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3.5 Puller

When we disassemble the motor we used puller to remove the bearings. So I practiced to remove the bearings
from the shaft that it’s mounted.

Figure 3.6- Puller

Puller is used to remove the bearings, the sketch of the puller shows in figure 3.6 sprockets from the shaft
without damage to those parts. There are various type of pullers used in our factory according to requirements.

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