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Detailed explanation of motor winding embedding process

Date:2023-11-07   Author:XINDA MOTOR

Wire embedding is a very important link in the motor winding rewinding process. Based on past experience in the motor production process, it is known that the wire embedding process is a key process that affects the quality of the motor. At the same time, the motor winding coil embedding is another meticulous work. In order to better complete the motor winding coil embedding work, the following steps should be followed and the precautions should be strictly observed.

1Preparation work before going offline

(1) Prepare common tools such as crimping plates, scribing plates, elbow scissors, pins, hammers, bamboo boards, etc. The crimping plate should be equipped according to the shape of the motor slot, and the scribing plate should be able to fit into 2/3 of the slot. , the pins should be able to facilitate the insulation along the edges of the stacked slots. Tools should be smooth to avoid damaging wires and insulation.

(2) Prepare slot wedges and insulate between layers and ends.

2 offline

1. When taking off the line, straighten the upper lead wire, put on the insulation sleeve, and pay attention to the direction of the lead.

2. In order to embed the coil neatly, use your right hand to flatten the line to be embedded before entering the slot. At the same time, pinch the lower end of the coil with the left rod and twist it in the opposite direction to make the outer part of the coil slightly twisted. Place the flattened coil in the middle of the slot insulation (and put a layer of guide paper first). Hold the coil with your left hand and pull it inward into the slot. The remaining wires can be drawn into the slot with a scribing board. During the offline process, You must be careful and use appropriate force to avoid damaging the insulation. Keep the wires in the slot neatly parallel and not intersecting. Do not shift the insulation in the slot to prevent the wires from hitting iron at the corners.

3. The edge of the coil that is not in the slot for the time being is placed on that slot (equivalent to a pitch). Paper should be placed under the edge of the coil to prevent scratches on the insulation.

4. Starting from the first lower edge, press the end of each coil downward and flatten the end to facilitate the embedding of the second coil.

5. Follow the upward method and continue to embed the lower edge of the second coil. After placing a set of lower edges, place the interlayer insulation in the slot until all the coils are embedded.

6. The extended parts of the end coils should be equal and parallel to each other. The winding plane should be 1.5-3 mm lower than the core and have a neat and beautiful bell mouth.

8. Use the crimping plate and the folding slot to insulate, and drive the slot wedge into the slot. When driving the slot wedge, place a piece of paper underneath to avoid damaging the insulation. The slot wedge must be appropriately tight.

9. After all the windings are embedded, cut off the excess part of the interphase insulation, use a rubber hammer or an ordinary hammer to cushion the bamboo board, and trim the end coil into a bell mouth, so as not to touch the end cover and allow the rotor to penetrate freely. When correcting, the force should be light and even, and the insulation of the coil should not be damaged. After correction, the outer ring of the end should be neat and the wires should not cross.

3 Connect the winding group terminals

1. Carefully check whether the wiring matches the original motor wiring.

2. Put an insulating sleeve on the wires to be connected, scrape off the insulating paint on the parts to be connected, and then twist the wires tightly for welding. The welding part should not be too long. For larger copper wires, they should be pre-finished. Use tinned copper sheets to make a headgear, or tie them tightly with thin copper wire before welding.

3. The connections should be staggered, the leads should be as close to the junction box as possible, and the connections should be neat for easy wrapping and beautiful appearance. The lead wire should be selected according to the rated current of the motor , but the current density is 2-3 times lower than that of ordinary wires. The cross section should be selected according to the table below.

4 connection wire welding

1. When soldering low-voltage motors, use rosin or neutral solder paste, and do not use corrosive solder paste. When welding, the solder must be thoroughly absorbed, the welding head must be firm and smooth, and molten tin must be prevented from falling into the coil.

2. For motors with larger capacity, phosphor bronze or silver solder should be used. The motor wire nose should be in good shape and the welding should be firm.

3. After all the connecting wires are soldered, you should comprehensively check whether there are any errors in the wiring. It is best to use three-phase low-voltage alternating current to pass into the stator coil, and place a round iron piece mounted on the shaft that rotates evenly on the stator to check whether it can rotate to determine whether the wiring is correct.

4. Put all the welded joints in the chamber with insulating sleeves, wrap them with insulation, arrange them neatly, and tie them tightly with cords or white gauze tape.