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In electrical engineering, coil winding is the manufacture of electromagnetic coils. Coils are used as
components of circuits, and to provide the magnetic field of motors, transformers, and generators, and in the
manufacture of loudspeakers and microphones. The shape and dimensions of a winding are designed to fulfill
the particular purpose. Parameters such as inductance, Q factor, insulation strength, and strength of the desired
magnetic field greatly influence the design of coil windings. Coil winding can be structured into several groups
regarding the type and geometry of the wound coil. Mass production of electromagnetic coils relies on
automated machinery.
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
References
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.
Wild winding
The wires are placed helically in every layer. Owing 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 Helical winding
when the voltage difference between the layers exceeds the voltage strength of the
copper wire insulation.
Orthocyclic winding
Owing to the fact that the winding should be mostly positioned parallel to the winding flange, meeting an
orthogonality condition, it is necessary to adjust the winding width to the number of turns per layer of the
winding. In particular for non-circular shaped coil cross-sectional areas, it is desired to locate the crossover
area to the small side of the coil body, also called winding head. This is due to the fact, that non-circular coils
are being mounted on a sheet metal package or in a circular arrangement. The coils should be rather small, in
order to avoid a contact with the neighboring coil or the sheet metal package. For orthocyclic round coils three
winding geometries can be defined:
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.
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
- gauge – wire tolerance
- number of turns per layer
- nominal wire gauge including the varnish coat (CuL)
This corresponds to about half the wire tolerance according to the specification of the German standard
DIN46435.
Even if the demands for low tolerances of the wire and the winding space had to be observed with
correspondingly high technical effort, there would still remain the problem that the wire guiding on the
machine side has to follow the previously described winding design also at high winding speeds. In practice,
this is hardly possible at high winding speeds since, e.g., at 18.000 windings per minute, the wire guide for a
wire with a thickness of 0.3 mm would need to 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 is particularly 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. Owing 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. Owing 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.
Design of an orthocyclic winding
The design or interpretation of the required space of an orthocyclic winding is usually realized by applying an
iterative approach. At first, the specified parameters of the required number of windings, the required wire
cross section and the maximum space available for an insulated coil are used for the calculation basis.
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:
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.
The fill factor measures the ratio between the volume of a winding b=8,85 mm; e=1,78 mm; c=1,86
package and the volume needed to house the winding pack. For this mm; d=0,334 mm; winding structure
purpose, it is necessary to take the required space for the rotation calculation example for an
diameter of the coil in the "cross over section" into consideration. orthocyclic area. 150 turns in 6
layers with 26 turns per layer and an
equal number of turns per layer
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
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.
Owing 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.
Linear Winding Termination pillar for a Wire parking pillar for Linear winding
coil a winding machine machine from the
company Fa.
Aumann GmbH
Flyer winding
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.
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.
Antriebsschema Winding Winding
Nadelwickelmaschine; nozzle in nozzle in
patentierter Pleuelantrieb winding position for
Fa. Aumann position termination
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.
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).
With the toroidal core winding technology an electric coil or winding is created by winding an electrical
conductor (e.g. copper wire) through the circular ring and evenly distributing it over the circumference
(Toroidal inductors and transformers, toroidal chokes).
Before the winding starts, the Toroidal / Magnetic core is mounted into a holding fixture that can initiate a slow
rotary movement of the core with mostly three rubberized points of contact. A wire storage ring (orbital wheel)
arranged 90° to the toroidal core will now be opened at the circumference and introduced into the center of the
toroidal core. The wire is then coiled around the wire storage ring that was closed again. When the required
amount is present on the wire accumulator, the end of the wire from the wire accumulator is fixed to the
toroidal core that needs to be wound. By simultaneous rotation of the toroidal core and the wire accumulator
ring, a winding develops that is distributed along the circumference of the toroidal core. Upon completion, the
wire accumulator has to be opened again in order to be able to remove the ready wound toroidal core. Since
the start and end wire are often not fixable to the toroidal core, toroidal winding machines can only be partly
automated.
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.
Hairpin winding has been widely used in electric motors in the Stators with different winding
automotive sector. This winding method offers the advantage of topologies
automated winding process. However, the large size of the conductors
are prone to proximity losses resulting in high winding AC loss.[1]
Similar method, plug-in winding, has been proposed where the coils are pre-made with plug-in features (male-
female). Compared to hairpin, the plug-in method offers the advantages of automated winding process and
small conductors size, however, the disadvantage of high contact resistivity in the plug-in connectors could
result in a thermal hot spots.[2]
Examples for different Designs of EC-Stators (Source: Technoexpert Dresden)
Asynchronous motors with distributed winding account for the major share of electric motors. Unlike the
concentrated winding, not every tooth pole is wound in a distributed winding; instead, coils are in slots and
span multiple pole teeth. Since the winding may block slots from further insertion of wire, it may be necessary
to wind a complete phase winding at one time.
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
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.
Wound Wound and Schematics of the insert
winding formed winding technqiue
head after head of
the distributed
insertion winding
process
In case of stator windings that are electrically commutated or supplied by an m-phase net, these phase
windings are often banked (distributed windings). The number of holes q constitutes a characteristic dimension
of the winding setup. It states how many slots q per phase m and pole (provided by pole number 2p) are
available.
q = Number of holes
N = Number of grooves
2p = Number of poles
m = Number of phases
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:
Manufacturing process of concentrated windings for stator coils
• 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.
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.
Basically, there is also a variety of different ways of insulation for outside slotted stator laminations as it is for
inside slotted stator laminations:
Verschieden isolierte Vollblechschnitte
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 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.
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 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.
Three workpiece carrier with each one pole chain and a wire
guide for a parallel winding of the phases U,V and W
Owing 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. Owing 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.
Electric motors must be compact and lightweight. They should also deliver a higher output with less copper
usage. A prerequisite for this is an appropriate design of the coil body and suitable wire dimensions. One
parameter of importance for the developer of motors is the electrical fill factor. The fill factor measures the ratio
between the volume of a winding package and the volume needed to house the winding package. In case of
stators, it can be said that the electrical fill factor is the ratio of the content of non-ferrous metals of the stator
including the stator slot to the sum of the uninsulated copper cross sections. But in contrast to round coils, only
the stator slot is considered. The reason for this is that merely the conductor strands in the stator slot contribute
to the torque of the motor. The winding overhangs on the narrow sides of the winding cross section of a tooth
only result in unwanted losses in the form of increasing electric resistance and undesired heat development.
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.
Given: Wire-Ø Cu 0,5mm 38 turns, non-insulated winding space = 41mm^2
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.
References
1. "9:11 Magazine Episode 14: HAIRPIN TECHNOLOGY" (https://www.youtube.com/watch?v=p
mWFt0_RUoU).
2. "Plug-In Winding for Electrical Machines and Electromagnetic Devices" (https://fluxmakers.wixs
ite.com/website/case2).