Professional Documents
Culture Documents
Contents
Principles
Wild winding
Helical winding
Orthocyclic winding
Location and size of the crossover section
Manufacturing orthocyclic windings
Design of an orthocyclic winding
Calculation example
Calculation of the fill factor
Winding processes
Linear winding
Flyer winding
Needle winding technology
Toroidal core winding technology
Winding technology for motor coils
Trends in motor winding technology
Manufacturing process of distributed winding
Characterization of distributed winding
Manufacturing process of concentrated windings for
stator coils
Definition of the fill factors for motor coils
Winding space examination of concentrated windings for
stators
Example for calculating the fill factor of a stator
lamination
Bibliography
Principles
Efficient coils minimize the materials and volume required for a given purpose. The ratio of the area of electrical
conductors, to the provided winding space is called "fill factor". Since round wires will always have some gap, and
wires also have some space required for insulation between turns and between layers, the fill factor is always smaller
than one. To achieve higher fill factors, rectangular or flat wire can be used.
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Wild winding
With this type of winding structure only poor fill factors can be
achieved. The random wire placement leads to a wider
distribution of resulting wire length on the coil body and
consequently a wider range of electric coil resistances. Despite its
disadvantages, it is common in mass production. It is
characterized by low demands for machinery and operator and
can be wound with very high speeds. Wild windings are mostly
applied in contactor- and relay coils, small transformers, Ignition
coils, small electrical motors, and generally devices with relatively
small wire gauges up to 0.05 mm. Achieved fill factors with the
use of round wires are about 73% to 80% and are lower compared
to orthocyclic windings with 90%.
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Helical winding
The wires are placed helically in every layer. Due to the direction of movement from layer
to layer changing between right-hand and left-hand, the wires cross and locate
themselves within the gap of the layer underneath. A wire guiding of the lower layer is not
existent. If the number of layers exceeds a certain limit the structured cannot be
maintained and a wild winding is created. This can be prevented with the use of a
separate layer insulation, which is needed anyway when the voltage difference between Helical winding
the layers exceeds the voltage strength of the copper wire insulation.
Orthocyclic winding
This type of winding structure creates an optimal
fill factor (90.7%) for round wires. The windings
of the upper layer need to be placed into the
grooves provided by the lower layer.
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The choice of the winding structure to be used basically depends on the design of the coil or the coil body. Among
others, the available space conditions for winding width and winding height must be considered. Moreover, it is
possible to influence the location and the end of the last winding by selecting a clever winding pattern. The winding
height of an orthocyclic coil winding results from the following equation:
-Winding height
- Number of layers
- max. wire gauge above the varnish (CuL)
Since an orthocyclically wound coil with at least 300° of the circumference of winding layers has the tightest circle
package of the wire cross-sections. This winding method reaches the highest fill factor and is the best way to fill the
available winding cross-section with round wires. Square coils are seen as orthocyclically wound when the winding
and layer jump occur only on one of the sides of the winding cross-section. In theory, a geometric fill factor of 0.91 will
be reached. In practice, however, the value cannot be reached because there exists a winding jump and layer jump area
and the wire insulation is not taken into account.
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fill factor = = =
= 0,907
In general, it can be stated that the requirements that need to be fulfilled for orthocyclic windings are very high. The
summation of all tolerances has to be kept at a very low value. Consequently, the following values can be named as
indicatory values: a) Tolerance of the winding space width
b) Tolerance of the wire Max. wire diameter tolerance should not be larger than
This corresponds to about half the wire tolerance according to the specification of the German standard DIN46435.
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perform a winding pitch in only 0.7 ms. The problem is amplified by the fact that in practice the ideal wire is never
absolutely straight. These unevennesses and bends resulting from the winding of the wire on delivery rolls have the
effect that the wires are never completely close together according to their actual diameter but at a distance according
to their unevenness.
This gap formation is additionally influenced during the winding-up of the wire by the surface quality of its coating,
e.g. the sliding behavior as well as by the expansion behavior or stiffness of the copper. The wire elongation may be
between 6% and 3% depending on the wire diameter and the supplier. Practice has shown that an orthocyclic winding
can only be manufactured in an acceptable way when choosing a very high wire elongation level (stretching leads to a
straight or even wire) at the beginning. For the reasons described above, it is therefore in practice impossible for the
wire guide to determine a precise gradient according to the wire diameter.
These unpredictable circumstances may be prevented or counteracted at the beginning of the winding by forcing the
wire, meaning, every single winding of the first layer on the inner coil diameter, into a predefined position. The wire
places itself into a prefabricated groove geometry of the coil body and the wire guide does not need to follow it exactly
but only approximately. Since the wire always loses in cross-sectional area due to the wire drawing to be used and the
necessary deflections (mechanical stresses under tensile load) during winding, the distance between the grooves is
designed only for the max. possible wire diameter. Effects of bends and tolerances of the wire and the coil body as well
as changing surface qualities can be avoided that way. Especially wire bends that develop due to wire deflections
caused by, e.g., pulleys, wire eyelets or even the wire guiding nozzle itself within the wire feeder of a winding machine
can lead to deformations that remain on the winding of a coil. Applying grooves to the winding basis supports the
layer-accurate position of the wire during the winding process. This behavior isparticularly beneficial for the winding
processes where a plastic deformation of the wire is unavoidable immediately before the depositing of the wire onto
the winding basis. This behavior can be observed especially in the needle winding technology. Due to physical reasons,
it is unavoidable that the wire leaves the wire guiding nozzle at an angle of approx. 90°. Therefore, mechanical
tensions remain inside the wire that are visible in the form of a bent winding on the winding basis. As a result, the
following windings or also the following layers can change in their desired position.
Starting from the second layer, the relocation is facilitated, since the wire is guided through the inter-spaces of the
preceding layer. In case of deflections that are not too excessive as far as the process is concerned, the wire leads itself
and with a constant number of windings per layer. It means for the wire guiding movement that the smaller the
distance of the wire guiding nozzle towards the coil, the more precise the tracking must be. In certain circumstances it
can be completely performed without a relocating movement, if the distance from the nozzle to the coil is that long
that the force component against the guiding behavior of the wire itself has no longer an effect. Due to the self-guiding
behavior of the wire, it is therefore possible that also during orthocyclic winding the wire guide can run continually
and does not need to follow gradually.
Calculation example
An orthocyclic winding design for a round coil with 150 windings, a wire diameter of 0.3 mm and a maximum winding
width of 9 mm shall be calculated. The winding diameter at the winding base measures 8 mm.
Given:
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f) Calculation of the outer dimensions of the coil in the cross section area
Summary of results: The calculation showed that the space needed for the purely orthocyclic winding with enameled
wire fills a rectangular area that measures 1.86 mm x 8.85 mm. Taking into account the assumption that it is a round
coil with an inner diameter of 8 mm, then, the outer diameter is 11.72 mm. The winding space constraints (flanges of a
coil body) of a winding support must have a diameter of at least Dmin=11,72mm considering the layer jump area.
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The imaginary space with the dimensions of 8,85 mm x 1,86 mm contains an area of 16.461 mm². The sum of all
partial spaces of the insulated turns equals
A = Amount of partial spaces of the insulated wires DL= wire gauge above the varnish n= number of turns
The imaginary space with the dimensions of 8,85 mm x 1,86 mm contains an area of 16.461 mm². The sum of all
partial spaces of the not insulated turns equals
n= number of turns
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Winding processes
Linear winding
In the linear winding method, a winding is produced by winding the wire onto a rotating coil body, component or coil
carrying or coil forming device. The wire is pulled from a supply roll that contains 400 kg enameled copper wire. The
wire is fed through a guiding tube. Before starting the actual winding process, the wire is mounted to a post or a
clamping device of the coil body or winding device.
By the linear laying movement of the wire guiding tube, the component to be wound is turned in a way that the wire is
distributed throughout the winding space of the coil body. The rotary motion as well as the laying movement is
achieved by using computer controlled motors. In relation to one rotation of the rotation axis and depending on the
wire diameter, the traversing axis of the wire guiding tube is moved accordingly (traverse pitch).
In doing so, rotational speeds of up to 30,000 1/min can be reached, especially when processing thin wires. Depending
on the winding diameter, wire speeds of up to 30 m/s are achieved during the winding process. The components to be
wound are mounted on so-called winding devices. The winding devices are coupled to driven spindles that generate
the turning motion. Since bringing the wire into the winding area should be done as evenly as possible, the rotational
axis and the traversing axis operate synchronically during the winding process.
In order to be able to control the positions of the wire guiding nozzle in relation to the component to be wound, even
with different component geometries, normally three CNC axes are used for the method with a wire guiding nozzle.
This enables the terminating to coil body posts (the posts are also intended to make contacts by soldering or welding):
By letting the three axes run in a way that a spiral movement of the wire guiding nozzle around the initial winding post
is resulting, it is possible to fix the start or end wire of a coil by the so-called termination. To keep the wire under
tension when changing the product, it is fixed to a wire parking pin of the machine.
This wire parking pin can either be a clamp or a copy of a post that is wrapped at the coil similar to the termination
process. Before the winding starts and after terminating the start wire post, the wire to the parking pin needs to be cut.
This takes place according to the wire thickness by tearing or cutting.
Enameled copper wires up to a diameter of approx. 0.3 mm can be torn normally by a tearing pen that passes close to
the post of the coil or the wire guiding nozzle itself. The separating point should be very close to the post of the coil in
order not to impede a subsequent contacting process (soldering, welding etc.).
Since all the movements during winding are directed via CNC axes, it is possible to realize wild windings, orthocyclic
windings or other winding geometries (e.g. cross-coils). The wire guiding control can often be switched between
continuous and gradual movement.
Due to the separation between wire guiding and rotation of the component to be wound, the configuration of product
and wire guiding can be duplicated in the linear winding technology. Therefore, it is possible, e.g., to wind onto 20
spindles simultaneously. This makes the linear winding method a very efficient process since the cycle time for
producing a component results from the quotient of the winding process cycle time and the number of used spindles.
The linear winding technology is often applied efficiently where low-mass coil bodies have to be wound.
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Linear Winding Termination pillar for a coil Wire parking pillar for a Linear winding machine
winding machine from the company Fa.
Aumann GmbH
Flyer winding
In the flyer winding method, a winding is
produced by feeding the wire via a roll or
through a nozzle that is attached to a so-called
flyer that is rotating at a certain distance from
the coil. The wire is fed by the flyer shaft. For
winding the component to be wound, it needs to
be fixed inside the winding area of the flyer. It is
necessary that the wire is fixed outside of the
flyer at any time of the winding procedure. The
fixation of the wire is made possible normally by
the so-called successive winding method (often
used at rotary indexing tables): At the
circumference of the table are wire clips or wire
deflections that enable a pulling along and with
it a fixation of the wire. This will allow a very quick component change, given that no separate depositing of the wire in
a wire clip on the machine is required.
Because the last guided point of the wire is located at a nozzle or roll of a flyer arm which is moving on a fixed circular
path that can only be shifted in laying direction, a precise laying close to the coil surface is impossible. As a result, it is
not easily possible to clearly lay down or even to terminate the start and end wires onto the component to be wound.
But it is certainly possible to produce also orthocyclic coils with the flyer winding process. Here, a self-guiding
behavior of the wire on the coil surface is an advantage.
As the component to be wound has to be presented only in the winding position and otherwise does not need to
perform any movement during the winding process, also very bulky and massive products can be manufactured. One
example is the rotors of electric motors (rotor winding technology, special form of the successive winding method):
The wire is held by a clip fixed to the machine during the component change. Since the rotors often consist of heavy,
punch-packed metal sheets, the flyer winding technology is of particular advantage in this regard. Since the flyer
cannot be directly guided in case of the rotor winding technology, the wire is guided across polished guiding blocks
into the corresponding groove or slot. Special wiring sleeves ensure the correct wire position at the terminals of the
Commutators.
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groove channel between the two neighboring poles of the motor to drop the
wire in the desired place. The stator is then turned at the reversal point on
the winding head by one tooth pitch so that the previous process can run
again in reverse order. With this winding technology a specific layer
structure can be realized. The disadvantage is that there must be a
clearance between two adjacent poles with a size of at least the nozzle
diameter. The nozzle diameter is about three times the diameter of the
winding wire. The space between two adjacent poles can therefore not be
filled completely.
Determination of the necessary
An advantage of the needle winding technology is the fact that the needle groove slot width depending on the
wire gauge (Source: Aumann
support carrying the wire guiding nozzle is normally coupled to a CNC
GmbH)
coordinate system. This allows moving the nozzle through space towards
the stator. This way, it is possible to also perform a laying movement apart
from the normal lifting motion and the rotation of the stator. A targeted
placing of the wire is nevertheless only possible to a limited extend since
the wire is pulled at an angle of 90° from the wire guiding nozzle resulting
in an undefined bulging.
The 90° redirection of the wire when exiting the hollow needle stresses the
wire a lot and makes it difficult to wind copper wires with a diameter of
more than 1 mm in a reasonable way. Orthocyclic winding with a needle
winder is therefore only partly possible for these winding tasks.
Inner-grooved stator with six poles
Since the wire guiding nozzle can be moved freely throughout the room, it
is possible for the nozzle to terminate the wire at the contact points if
equipped with an additional swivel device. As in the case of the conventional linear winding technology, a contact pin
or a hook contact can be terminated for the electrical connection and for interconnecting the single poles in a star
connection or delta connection.
A precise synchronization of the rotary motion with the stroke movement is required so that the needle does not touch
the groove channel during the up and down movement. Influencing variables for the maximum winding speed are the
needle stroke, the rotation angle of the stator (number of poles), the wire diameter and the groove channel width and
the helix angle of the angularly grooved stators. The mass of the wire guide and the needle support experience a high
acceleration. This can lead to unwanted vibrations that have an effect on the winding quality. The lifting motion is
normally generated by ball screws. During this movement, the servo drives must constantly reverse in order to reverse
the direction of the needle movement.
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Another way of initiating the stroke movement is to apply a crank disk that can also have a stroke adjustment and that
uses the advantage of the sinusoidal movement pattern without needing a drive motor to reverse. Strokes (windings)
up to 2500 per minute can be achieved.
With the needle winding technology, it is possible to produce a finished assembly such as stator coils or a connection
and contacting onto a machine. Apart from the not fully utilized space between the poles, it is possible – in contrast to
the conventional pull-in technique – to wind also motor coils with a good fill factor onto low stator sheet stack heights
(coiler head heights).
Toroidal cores are used despite the high manufacturing costs (a great deal of manual work) due to the low magnetic
flux leakage (MFL – Leakage inductance), low core losses and the good power density. One possible quality feature of
transformers is a uniform distribution of the windings along the circumference (low stray field). The insulation
between the various windings can be solved quite differently. In case of covering windings, a film is applied after the
first winding to achieve good stray field characteristics. This film needs to be wound to cover the whole circumference.
For this, also toroidal winding machines with special magazines can be used.
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Coil insertion machines insert prefabricated groups of coils into the stators of electric motors. The coil groups are
frequently manufactured with flyer winding machines and put onto the insertion tool with a transfer instrument. In
small-batch manufacturing, the coil groups are relocated manually from the winding masks to the insertion tool using
transfer instruments. Subsequently, an insertion tool places the preformed winding into the stator slots. The slots are
sometimes insulated with paper. When diagonally winding the coil into the slot of the stator, the coil's internal width
must be larger than the stator's height which leads to the formation of the large winding head that is characteristic for
the insertion technique.
Process steps for insert technique: 1) Non equipped insert tool; 2) With coils
equipped insert tool; 3) Insert tool with coils and mounted stator; 4) Stator with
inserted coils
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This in turn results in a relatively loose winding in the stator slots. Consequently, it is necessary to close the slot
openings towards the middle of the stator with a so-called sliding cover. In many cases, this may be conducted
concurrently with the insertion of the coils. Since the coil's conductors have to pass through an oftentimes tight slot,
the coils consist of a certain number of small spare cross-sections which are later connected in parallel. It is with this
measure, that large conductor cross-sections may also be produced.
Another reason for using many thin conductors connected in parallel lies in avoiding the so-called Skin effect. In order
to keep the impact of this effect as small as possible, wires with the largest possible surface are used in high-frequency
technology, e.g. in the form of thin spare cross-sections or Litz wires. The low losses of Litz wires partly stem from the
fact that a large area of the inner surface is taking part in the current flow. In particular in electric mobility, the motor
is often powered by high-frequency voltage. When using large conductor cross-sections, this may possibly lead to high
losses and an undesired heat development in the stator winding.
After inserting the winding, rework on the stator or the winding ends needs to be performed. Usually, the multitude of
connecting lines is separated manually and bundled according to the different phases. Both winding ends are tied up
with an adhesive tape or strap in the further course of the finishing. When using a high operating voltage, the partial
winding of each phase must be insulated against the respective adjacent phase with foil or insulation paper. To ensure
that the winding heads are positioned exclusively at the back of the stator, both of them must be molded. This is either
executed by using an enameled wire receiving a bonding electric current during molding or by cold forming which is
followed by impregnation. The creation of a certain winding head shape allows a rotor to be installed or a stator to be
inserted into the housing afterwards.
q = Number of holes
N = Number of grooves
2p = Number of poles
m = Number of phases
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In the case of distributed windings, q ≥ 1, and if q is integer, it is an integral slot winding. If q = zq/nq is a fractional
rational number, it is referred to as fractional slot winding. When it comes to single tooth winding, q < 1 and thus
always a fractional rational number.
The winding scheme shows the execution of three-phase winding with 30 groups of coils at a winding pitch of 1:6 with
the same width at a star connection. The combination of the star connections is depicted in form of a circle on the
yellow contact bar. Each coil needs two slots. Consequently, 30 slots (coil groups) x 2 slots / group = 60 slots are
required in order to achieve a consistent occupancy of the slots. The number of poles amounts to 10. The respective
number of slots is determined by:
• Inside slotted stator laminations The needle-winding technique basically represents the only feasible winding
process for inside slotted stator laminations. The stator mainly consists of a steel package, two end plates and slot
insulation. The particular benefit of this process technology lies in the fact that the winding machine produces a
completely winded assembly group when adequate electrical slot fill factors are employed. If, however, the use of
single teeth requires joining and interconnecting operations, all interconnecting measures of the coil sections of one
phase may be executed by the winding machine for the stator laminations. In this case, the electric slot fill factor may
amount up to 45%. Since manufacturing a functioning stator merely requires a small effort, the negative impact on the
electric fill factor is gladly accepted. In order to be able to use various additional functions of the winding machine, the
end plates are often designed in a way which allows e.g. the taking on of cutting terminal contacts. In addition,
winding space restrictions and laying ducts for the connecting wires of a phase may be integrated.
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Example for a lead from for a full sheet metal package stator displaying several
design characteristics
The material costs are also low due to the small number of individual components. In combination with the modest
costs of the means of production, stator laminations constitute a practical solution. Three essential basic concepts
frequently come to the fore when dealing with the design of stator laminations. Stator laminations for concentrated
winding are divided into the following main groups.
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An extended form of the stator's end insulation with injected slot shafts
constitutes in the molded stator. In the last few years, injection molding
has progressively been developed. It now allows to place the stator package
into the injection mold and to facilitate the molding process. In doing so,
the wall thickness reached is similar to the one of the end plates with
injected slot shafts. A particular benefit of this process lies in the fact that a
pre-assembly of the end bells and the insulation paper can be avoided
which prevents the danger of insulation gaps that could lead to short
circuits. However, due to the very costly complex injection mold, costs are
only covered at a batch size of approx. 50.000 stators per year, compared
to single component insulation. In addition it must be noted, that the Concept for a coated stator
diversity in types is only conditionally lucrative since a new injection mold
needs to be produced whenever the length of the package or the
laminations changes.
Basically, there is also a variety of different ways of insulation for outside slotted stator laminations as it is for inside
slotted stator laminations:
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Segmented stator coils are used, for example, if a high winding number is
required in addition to the demanded high fill factor and the
corresponding orthocyclic winding. They are preferably processed with the
flyer-winding technique as well as with the linear-winding technique. For
this type of stator construction, it is particularly beneficial to produce
accurately layered windings with extremely high fill factors because of the
freely accessible winding space. However, the design of the segmented
stator coils has negative repercussions on the material and production
Polechain consisting of segments
costs. Often, complex processes need to be applied in order to form the
single teeth to a round stator. Another disadvantage constitutes in the large
number of contact points, except when the pole-chain winding technique is used.
For segmented stator coils, a distinction is made between T-segments and plugged engine coils. The latter may be
bodiless or winded onto a coil body and subsequently be transferred to a T-segment or directly to the stator
laminations, depending on the application. Contingent on the expected contact points, there are three different
options for the production of T-segments. For one, there is the classic single T-segment with the disadvantage of
having a high number of contact points. In addition, there is the phase winded T-segment with a reduced number of
contact points. Finally, there is also the winding of so-called pole chains with a drastically reduced number of contact
points.
a) T-segments
T-segments are preferably processed with the linear winding technique or the flyer-winding technique. For this, the
winding supports are designed in a way that a mounting at the tooth back can be carried out. It is in particular the
outer geometry that will serve as the contact surface of the adjacent tooth later on, which is used for securing the tooth
in the winding device. It is also quite common to place a dovetail slot in the outer part of the back of the tooth which is
axially arranged to the tooth and serves the purpose of securing the tooth in the winding device. Insulation of the
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winding of the T-segment may be performed the same way as for inside
and outside stator laminations which is either by paper insulation, end bell
insulation or as a molded tooth.
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d) Chains on poles (chained poles) With this kind of stator design they try to combine the benefits of the needle-
wound laminations => Minimum amount of contact points – with the advantages of the linear wound single tooth =>
Maximum fill factor.
For this, the chained poles winding technique is used that provides a very high fill factor due to the fact that the
structure of the stator is opened up into a linear arrangement of the single teeth and besides, in contrast to the
otherwise common single teeth, generates only a few contact points. The connecting wires of the coil sections of a
phase connected in series do not need to be separated.
When winding toothed chains, the flyer winding technique, also a type of needle winding and chain winding can be
used.
A disadvantage when using the flyer winding technique is the fact that only one tooth at a time can be wound. So,
toothed chains are developing as a result but due to the wiring topology most of the stators have to be undone again. A
simultaneous winding of multiple stator phases usually is not possible. If, however, the flyer winding technique for
toothed chains requires auxiliary tools for placing the wire into the winding space or the linear arrangement needs to
be given up when the winding of a single tooth takes place, the wire can be directly deposited with the needle winding
technique. A special benefit when using the needle winding technique is provided by the possibility to wind all three
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phases at the same time depending on the type of stator circuitry. Especially advantageous is the behavior of the
connecting wires between the coils of the individual phases at the rounding of the teeth if the linear arrangement of
the teeth for the winding does not need to be given up. Therefore, it is opportune to make sure that the connecting
wires pass through the center of the rounding radius.
Due to this smart arrangement of the wires, it is possible to avoid changes in the wire length during rounding. When
using the needle winding technique, it is quite common to wind multiple toothed chains simultaneously. This happens
mainly on carrier tools or workpiece carriers that are positioned inside the needle winding machine. Due to the fact
that the phases U, V and W as well as multiple stators can be wound at the same time, the needle winding technique
has a high performance density in connection with the use of toothed chains.
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An orthocyclic winding design for a stator with 40 windings per tooth at a wire diameter of 0.5 mm shall be calculated.
The available insulated winding space is geometrically defined and has a surface of 35 mm². An insulation paper with
a thickness of 0.25 mm is used.
Given: Wire-Ø Cu 0,5mm → CU1L=0,548mm (Value according to norm) 40 turns, insulated winding space =
35mm^2, insulation paper 0,25mm
When looking at the insulated winding space graphically and the required number of windings at a given wire
diameter, it can be said that considering the space requirements for the winding nozzle (required groove width: about
3*0.548=1.6 mm) only 38 windings can be introduced into the winding space of the stator slot.
• Determination of the electrical fill factor The theoretical consideration takes place by assuming that the uninsulated
wire is to be found in the uninsulated groove.
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Bibliography
Querfurth, William (1954). Coil Winding: A Description of Coil Winding Procedures, Winding Machines and
Associated Equipment. University of Michigan: G. Stevens Mfg. Company.
Gingery, David (1991). Build a Universal Coil Winding Machine. David J Gingery Publishing. ISBN 978-
1878087102.
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