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Kungta 3 Winding head 6 Station Automatic Induction Motor Coil winding machine

The impact of coil winding induced problems in strip processing is described and the common causes of those problems identified. The criteria for designing a suitable coil winding strategy are listed and the constraints arising in typical strip processing plants discussed. A simulation model is employed to facilitate the strategy investigation. Suitably defined dimensionless parameters are introduced to reduce the dimensionality of the problem and to yield novel insights into the internal stress distributions of wound coils and the effect of mandrel shrinkage during winding.

Finally, the effect of thickness profile and poor flatness upon the coil winding behaviour are described. The Mystery of Coil Winding. Previously strip was processed in sheet form through hot and cold rolling, annealing, temper rolling, galvanizing and corrugating. Even so, the handling of strip material in coil form is not without its challenges as will be illustrated in discussions of the fundamental principles of coil winding technology.

Coil winding and unwinding are the most frequent operations performed on flat strip material in its journey from the casting operation to the final manufacturing stage. So it is surprising that there is a negligible amount of information available which discusses the technology surrounding this operation compared with other companion processes such as rolling, annealing and coating. This situation would be understandable if there were no problems arising from coiling operations.

However, the reality is that in many plants, particularly older ones, the costs of yield loss, speed restrictions, non-standard processing. Whereas tens of millions of dollars are spent in upgrades of major processes to achieve modest yield gains, almost no resources are allocated to identifying, correcting and monitoring winding problems which are often responsible for a far greater loss of profit.

Why this situation has arisen is difficult to explain except that winding appears to be deceptively straightforward and there are few measurements normally available with which to analyse the operation apart from the winding tension. Operator practices are often contributory causes to winding problems and management are reluctant to tackle such issues. Two other explanations for the lack of action are that the impact of the problem occurs one or more operations downstream and, over a period of time, an acceptance of damaged coils and their consequences can become part of the local culture.

The information to be presented has been accumulated over a period of 25 years and will.

Download: Coil Winding Machine Gingery.pdf

During this time a simulation model for calculating the internal stresses in a wound coil was developed and has been used to explore the characteristics of the process and to investigate optimum coil winding strategies.

Subsequent sections of this paper will explain the application of this model to solving several common winding problems and provide a novel set of dimensionless parameters which simplify the task of designing an optimum winding strategy. The most frequent types of winding problems and their causes are also discussed. Discussion of Coil Winding Principles. Anyone who has tried to wind a streamer of paper tape from a free ribbon of material into a tight wound coil will have discovered that it requires a reasonable degree of dexterity.

Usually the sides of the coil are uneven and the coil does not behave as a solid cylinder unless the outer wrap is pulled tight enough to cause interwrap slipping which eventually results in a tightening of the coil wraps from the coil bore to the outer periphery. If the wraps are staggered when the coil is tight then it is difficult to push them back into alignment without damaging the wrap edges.

handbook of coil winding pdf

The same issues discussed above in relation to a paper tape streamer also apply to metal strip coils. That is, coils should have straight sides and should behave as an integral, solid body while being handled for finishing operations.

If inter-wrap slippage occurs during winding then scratching and surface damage often occur and there is a high probability of transverse movement of some wraps. The latter phenomenon is usually referred to as telescoping or dishing, depending upon the particular form of the resulting sidewall profile. Several examples are shown in Fig. In its more extreme form telescoping can present a significant danger to floor operators.

The likelihood of this occurring increases as the coil diameter increases so that the trend towards bigger coils may lead to a growth in the incidence of coil winding problems.Named after the inventor Nikola Tesla, Tesla coils are electrical devices designed to produce high frequency, high voltage alternating currents. Originally, Tesla used them as power supplies for his high frequency electric lamps. Aroundin response to a request from the U. Government for the development of a maritime wireless system, he adapted them for use as a major component of specially designed radio transmitting and receiving sets.

About the same time, he adopted the same design principle known as the resonant transformer in the construction of two very large oscillators used to conduct fundamental experiments in the global propagation of radio signals. The pioneer of radio, polyphase alternating current generation and utilization, and numerous related inventions essential to the modem age, Nikola Tesla was a maverick genius who towered over Thomas Edison in the late nineteenth century.

Plagued by obscure personality quirks and manipulated by some of the big fish in the financial and industrial establishments, Nikola Tesla would live to see his reputation fade and his assets dwindle before he died alone in Tesla was a brilliant star in American inventive history and the world owes him a great debt. Readers are encouraged to learn more about the rich history surrounding Tesla and the electrification of America.

The Tesla coil evolved out of a need to produce radio frequency RF signals more efficiently. The principle of resonance as embodied in Inductor - Capacitor LC circuits was fairly well understood and accepted within the scientific community throughout most of the nineteenth century.

The work of Wollaston, Helmholtz, and Kelvin tantalized other scientists about the world of high frequency currents. Later experiments by Hertz with simple tuned circuits responding to the waves produced by induction coils would hint at the possibilities of long distance transmission of signals through the air. But it was Tesla who used tuned and grounded induction coils RF Oscillators to produce devices efficient enough to usher in the age of radio. A Tesla coil is a resonating air-core transformer which produces bursts of high voltage, high frequency current that can emanate from its top in the form of loud and long lightning bolts.

A Tesla coil is an effective means of obtaining high voltages at high frequencies, but efficiencies seldom exceed fifty percent. Tesla began his experiments with the device, also known as a disruptive discharge coil, around Louis, he was able to use it to demonstrate the transmission and reception of strong signals without the use of wires.

Inin order to refine the apparatus and further carry out his experiments in radio propagation, Tesla built a giant version of his oscillator at Colorado Springs known as the magnifying transmitter.

In addition to providing radio communications, he felt that his system could be adapted for the transmission of electrical energy. Although we still rely upon power transmission lines for the distribution of electricity, the fundamental principles of earth resonance that were first established in Colorado Springs were the product of genius, and the design astounds researchers even today.

Tesla's pioneering work in the areas of electrical and mechanical engineering served to establish a number of prototype models that are available to be recreated and improved upon today. The Tesla coil is just one example. This book is intended to introduce electrical experimenters to the Tesla coil.

This book is not and does not pretend to be an advanced scientific text. Unlike Tesla's three phase induction motor and poly-phase generation and transmission system, much of the knowledge and theory behind the operation of his oscillators has been omitted from college text books and curricula.

Handbook of Coil Winding

Because the design has been filed away under the heading of academic curiosity only, little reliable information can be found about it.

Since publicly available grants are only allocated to projects with a well defined governmental or industrial need, much of the recently restored information that is becoming available in the field is the result of privately funded research.

Many of those who were interested in the theory and construction of Tesla coils had to resort to the world of Testa Literature as a source of information. Because of his intelligence, outspokenness and passionate vision of future technology, Nikola Tesla has, for better and for worse, become a folk hero for alternative technology enthusiasts as well as believers in esoteric free energy devices. While Tesla literature can be fascinating and evocative, it certainly isn't conventional science.

I'm not trying to pick any fights, but I don't believe that the Law of Conservation of Energy can be denied.The interactive PDF file must be downloaded. It will not work if it loads within your web browser. Self-paced, interactive training for stators volts or less.

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This valuable interactive training tool is ideal for training your novice s. Even experienced winders will learn from it. The CD teaches how to wind in a richly detailed, step-by-step approach. It includes narrative, animations and video clips, with tests to assess student comprehension. The training, which is divided into 13 lessons, covers data taking, core testing, coil cutoff, burnout, stripping, core preparation, coil making, stator insulation, coil insertion, internal connections, lacing and bracing, inspection and test of untreated and treated windings, and winding treatment.

Features include "Pro Tips" and "Drill Downs" that enhance the learning experience and assure that even the most experienced technician will learn from this product.

The course is delivered as an interactive Adobe PDF file containing text, audio, video, supporting documents and quizzes. The course is primarily intended for new winders with little or no winding experience.

It can also be used for reinforcement and expansion of more experienced winders knowledge of random winding. Further, many of the techniques and principles used for three phase random windings can also be applied to armatures, wound rotors, field coils, and form coil stator windings.

The software is interactive, and self-paced. You can repeat each section as many times as you like, until you are comfortable with the material. The lessons generally progress in the same order as the winding work, though there are some exceptions, and include narrative, animations and video clips, and tests to assess student comprehension.

Other features include "Pro Tips" and "Drill Downs" which are designed to enhance the learning experience.

Objectives Of The Course The primary objectives of this interactive course are to provide the student with necessary information on the methods, materials and tools to properly rewind a three-phase, random wound stator. Further, to teach the student i. The ultimate objectives are for the student to become an accomplished winder.

For the student to succeed in learning to wind, a necessary complement to the course is actual hands-on winding. A mentor, such as an experienced winder or supervisor, should guide the student through the hands-on winding activity. The mentor can also instruct the student on the practices specific to their service center. To put the winding curriculum in its full and proper perspective, here we will detail the objectives of each lesson. Lesson 1: Taking Data In the first lesson, Taking Data, the key objective is to accurately determine winding data for a three phase stator, including connection, turns, span swire sizes, poles, and grouping; and core and coil dimensions.

It is important that the new winding data match the original so that the motor produces the same performance characteristics e. Further, it is important to note that some of the critical data cannot be determined later in the winding process.Hello everyone, i am Niko and, in this instructables i will show you, how to rewind and renew old three phase electric motor. If you are searching for rewinding of one phase motor you can find it here.

In this insctructables, i am going to make step forward. In next steps I will show you how to analyse motors winding, disassemble motor, remove bearings, calculate new winding, rewind motor, reassemble it with new bearings and test motor. Rewinding is very long process. It took about two days to rewind it, replace all old parts and reassemble it.

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Did you use this instructable in your classroom? Add a Teacher Note to share how you incorporated it into your lesson. Three phase asynchronous motor is most common used motor in the world. It has very good efficiency and low manufacture and maintain costs.

Two main parts of motor are rotor and stator. Rotor is usually made as squirrel-cage, and it is inserted in stators hole. Stator is made out of iron core and winding. Stator is used to generate magnetic field. Rotation magnetic field "cut" squirrel-cage, where it induces voltage. Because cage is short-circuited, voltage generates flow of electric current.

Current in magnetic field generates force. Because magnetic field must rotate faster than rotor to induce voltage in rotor. That's why motor speed is a little bit less then magnetic field speed rpm [Magnetic field] -- rpm [Electric motor].

Before measuring remove all connections in conduction box. Measure resistance for each winding, resistance between two different winding and resistance between winding and motors frame. Resistance between two winding and winding - frame should be more than 1,5 Mohm. Take few picture of motor.

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Mark spots between first cover and stator and second cower and stator we will need this marked points at motors assemble. Remove covers from motor. Usually they are attached on stator by long screws. If you cant separate cover and stator you can use rubber hammer. Gently hit cover and try to rotate it.A word in response to the corona virus crisis: Your print orders will be fulfilled, even in these challenging times.

handbook of coil winding pdf

This book presents the current coil winding methods, their associated technologies and the associated automation techniques.

From the introduction as a forming joining process, over the physical properties of coils, the semifinished products wire, coil body, insulation are introduced. In the process chain, different winding methods are used for magnet wire winding. Finally, the automation of these processes is described. Sincehe has been working on the process development at Aumann GmbH. JavaScript is currently disabled, this site works much better if you enable JavaScript in your browser.

Free Preview. Helps in design, procurement and operation of winding machines Illustrates the complete winding process with more than detailed presentations Covers the theoretical and practical aspects of coil winding technology Offers many tips and suggestions for a production-friendly product design see more benefits. Buy eBook. Buy Hardcover. Buy Softcover. FAQ Policy. About this book This book presents the current coil winding methods, their associated technologies and the associated automation techniques.

Show all. Read this book on SpringerLink. Recommended for you. PAGE 1.The criteria for designing a suitable coil winding strategy are listed and the constraints arising in typical strip processing plants discussed. Special attention is given to the development of head end tension practices, often referred to as hardcore tension policies, which minimise coil collapse and coil telescoping frequencies.

A simulation model is employed to facilitate the strategy investigation.

handbook of coil winding pdf

Suitably defined dimensionless parameters are introduced to reduce the dimensionality of the problem and to yield novel insights into the internal stress distributions of wound coils and the effect of mandrel shrinkage during winding. Finally, the effect of thickness profile and poor flatness upon the coil winding behaviour are described.

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When the first hot rolled coils were produced off the ARMCO Butler hot tandem mill in the s it opened up a new era in metal strip production.

Previously strip was processed in sheet form through hot and cold rolling, annealing, temper rolling, galvanizing and corrugating. Even so, the handling of strip material in coil form is not without its challenges as will be illustrated in discussions of the fundamental principles of coil winding technology. Coil winding and unwinding are the most frequent operations performed on flat strip material in its journey from the casting operation to the final manufacturing stage.

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So it is surprising that there is a negligible amount of information available which discusses the technology surrounding this operation compared with other companion processes such as rolling, annealing and coating. This situation would be understandable if there were no problems arising from coiling operations. However, the reality is that in many plants, particularly older ones, the costs of yield loss, speed restrictions, non-standard processing.

Whereas tens of millions of dollars are spent in upgrades of major processes to achieve modest yield gains, almost no resources are allocated to identifying, correcting and monitoring winding problems which are often responsible for a far greater loss of profit.

Why this situation has arisen is difficult to explain except that winding appears to be deceptively straightforward and there are few measurements normally available with which to analyse the operation apart from the winding tension.

Operator practices are often contributory causes to winding problems and management are reluctant to tackle such issues. Two other explanations for the lack of action are that the impact of the problem occurs one or more operations downstream and, over a period of time, an acceptance of damaged coils and their consequences can become part of the local culture. The information to be presented has been accumulated over a period of 25 years and will. During this time a simulation model for calculating the internal stresses in a wound coil was developed and has been used to explore the characteristics of the process and to investigate optimum coil winding strategies.

Subsequent sections of this paper will explain the application of this model to solving several common winding problems and provide a novel set of dimensionless parameters which simplify the task of designing an optimum winding strategy.

The most frequent types of winding problems and their causes are also discussed. Anyone who has tried to wind a streamer of paper tape from a free ribbon of material into a tight wound coil will have discovered that it requires a reasonable degree of dexterity. Usually the sides of the coil are uneven and the coil does not behave as a solid cylinder unless the outer wrap is pulled tight enough to cause interwrap slipping which eventually results in a tightening of the coil wraps from the coil bore to the outer periphery.

If the wraps are staggered when the coil is tight then it is difficult to push them back into alignment without damaging the wrap edges. The same issues discussed above in relation to a paper tape streamer also apply to metal strip coils. That is, coils should have straight sides and should behave as an integral, solid body while being handled for finishing operations. If inter-wrap slippage occurs during winding then scratching and surface damage often occur and there is a high probability of transverse movement of some wraps.

The latter phenomenon is usually referred to as telescoping or dishing, depending upon the particular form of the resulting sidewall profile.Toroids with many turns of secondary winding are very useful for AC current sensing and measurement because you can just pass the wire carrying the current to be measured thru them. Well, unpleasant unless you have one of these cool toroid winding machines. After I finally figured out how the machines work, I thought about building one.

But there are too many strange and precision parts, especially if you want to wind small cores — which I do. So how do you quickly and simply wind wire on a closed loop toroid? Well, duh — you cheat.

handbook of coil winding pdf

Fortunately, a ferrite core is kind of brittle, and if you score it nicely, it will often break fairly cleanly. The first was to just saw halfway thru before cracking it. The material cuts very nicely with a hacksaw. That approach provided a nice break, but lost so much material that it really felt like performance of the core would be compromised.

Rewinding 3 Phase Motor

I never bothered to wind it. In the spirit of scoring plastic, I tried a Stanley knife. In any event, scoring the outside and inside! I generally held the core in a vise and whacked it to effect the break. Results varied from about perfect to needing some additional reassembly. By clamping the pieces together tightly, the gap should be small enough to not hurt the magnetic properties too much.

When there are chips, it may be easier to glue the chips back carefully as a separate step before you put the two halves back together. If there are chips missing, abort and try a new core.

While you could wind the secondary by hand, my strong first choice would be to let a drill or something turn the core while I guide the wire. Most of the winding will be about midway between the two breaks, so that part should be on the centerline of the spindle to minimize wobbling. You could use a dowel nicely shaped concave to fit up against the core as the spindle, but the bottom would probably underlap? If you handle it gently while winding, hot melt is a great way to hold the spindle to the core half temporarily.

Having a helper to count the turns is convenient. Another, probably less accurate approach is using an estimate of the average diameter of one turn of the winding and the desired turn count to compute how much wire it will take.

Thanks to Ti Leggett at Workshop 88 for the video. Having them all bunched up together is fine. Super glue seems good because the breaks are clean and it introduces such a minimal gap at the joints. Something like epoxy, that provides filler and some thickness to the glue joint would require that you clamp the core halves together quite tightly to squeeze out as much glue as possible. After you glue the core halves together, bring the ends of the zip tie around the top of the core and pull it tight.


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Handbook of coil winding pdf
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