How to rewind an electric motor

Want to know how to rewind a motor? Watch the entire electric motor rewind process with this video from the Gibbons Engineering Group workshop in Essex.
Visit: gibbonsgroup.co.uk/products-s...
#howto #electricmotorrewind #rewinds #motorrewind #rewindsworkshop #acmotor #howtorewindamotor #engineering

[@jamesdewer]

This brought back memories. In the Navy I was stationed on an Aircraft Carrier. As an Electricians Mates the best, most high dollar making rating after you got out. We must have had 1000 motors on that boat. Rewinding the dang things were only part of the challenge. The most memorable were the 100hp firemain pressurizers or 100hp aviation fuel pumps. Both were huge with stators large enough to pass a small man through. Located down in the lowest levels of the boat, as low as 7 decks down!!!! A crew of us Black men, white men, yellow men together as one. We pulled these massive motors out an to hell with the rocking of the boat. A single chain-fall motorized, above decks, clamped to the overhead using a pac-man or shackle. Below in the hole we used smaller 1/2 ton chain falls to remove and walk the massive chunk of steel to the watertight door. The chainfall above was run all the way out and we would simple drag the beastly motor to the door then out the door and up 7 stories the rocking of the boat, while unnoticeable to to us at the top was exponentially apparent looking down a shaft 100ft or more down. No whisky stick or tag line. Die in combat or get torpedoed? Sure, have the chain part and get flattened by a falling motor. You didn't even think about it. that motor beat the living hell out of every fixture coming top side. We had a donkey cart to push it to the shop. then down a deck to a waiting high temp over where we baked the entire thing in a waiting 600 degree oven melting the varnish off and the winding could easily be removed by hand once cooled. USS ENTERPRISE CVN-65. EE20. It took brains besides the brawn. "A" School was 18 weeks of intense study. The instructors did not brook incompetence. Even the smallest error re-paralleling a generator 10degs out of phase and you were out. It was stressful and we competed against Nuc-qualified electricians. They had to score higher than the smartest conventional. We bounced many and shared beers together with every Nuc we bounced. Lol. We never had an issue rewinding a motor. We surge tested them, turn off the lights and is the was evidence of arching or we had a spike in the display it was no go.

[@Ladellis]

Not sure if the old fella doing the rewind is just shy of the camera or loves his work that much it makes him smile. Great to see a professional at work.

[@ADudeNamedStacie]

That guy has been rewinding motors since dirt was new and rocks were soft. A lot of experience.

[@jackrichards1863]

Yeah! That is quite a long while !

[@paradoxdea]

This man is truly enjoying his job...amazing video!!!

[@GibbonsGroup]

Thanks for the nice comments!

[@grumpyg9350]

All that work, and he didn't even stop for a cup of tea. Amazing job and he even took the time to make sure the lashing was on the flat. 👍👍👍👍👍👍

[@janetc2241]

THAT GUY IS A MASTER. AWSOME, WHEN THEIR GONE LITTLE TO NONE WILL BE THERE TO STEP UP AND TRY AND DO AS GOOD AS HE HAS. I MISS THESE OLDER GUYS - SO MUCH TO LEARN FROM THEM.

[@Zapgod]

Yeah did you see how fast he ran that coil winding machine????? 😂😂😂

[@elams1894]

Nice to see seasoned pros at work, love the old school stuff, nice job!

[@adrianwabe5202]

That was neatly done.

[@gerryroberts662]

This guy still good at what he does, WOW.. Amazing re wireing a motor. so much goes into it. again Wow..

[@alzaabialzaabi]

This man has a lot of experience

[@farazsiddiqui6689]

Excellent work Sir.

[@surlasathibabu6781]

U R a great rewinder sir

[@benjamintuglo3895]

Please more of this God bless you

[@Iskraelektronik]

Great video :)

[@indikasuranga2211]

great work . very experience person

[@heroknaderi]

I enjoyed watching this is amazing 🤩

[@GibbonsGroup]

Thanks Kevin, we're glad you enjoyed it!

[@glenwoofit]

That's how I was trained to rewire a motor apart from we used to solder our connections. This was a pain in the the arse when you did the star point of a genset with around 1000 wires going into the lug.

[@dodznb238]

Hello my frind , sir have a good day...very nice jod...im allso rewinder dir..from philippines.. manual rewinding..injoy lang sapag rewind sir...thank you. I see in all video..

[@4starmotorwinding2]

Very nice broo

[@tukangrewinding]

Good job sir

[@skillselectrical]

very good I enjoyed Always be on top and successful

[@GibbonsGroup]

Thanks, we always try to do our best

[@diazlopez48]

Muy bueno, en lugar de fuego para quitar el alambre yo uso una mezcla de ACETONA Y THINNERS,el barniz afloja enseguida y evitamos dañar al estator

[@_paulmusyoka_]

The background song is cool.

[@hancecrawford]

Heating the stator laminations with a gas torch not damage insulation between laminations causing eddy curents inthe core

[@richardli5151]

it's an art

[@GM_ELECTRONICALS]

make sep by step procedure to learn from basic to final rewinding

[@runbou3485]

Thanks អគុណ

[@narendergodara1992]

Excellent vedio👌👌

[@adbogo]

What a load of rubbish. You can't learn anything from this video.

[@GibbonsGroup]

Are you trying to learn how to rewind an electric motor online? We do our best to document the work our rewinds engineers do, but it's almost impossible to do a step-by-step guide as there are loads of different motor types that need their own wiring configurations. This video isn't a comprehensive step-by-step guide. We do have some other videos that might help you though.

[@tacotele6819]

If only dry stripping was always that easy. But it was probably an aluminum housing.

[@randallvance1949]

Seems to be enjoying the work. Bet he's done a few...

[@uzairmasood977]

very nice . He loves his job .

[@kripalrajak9474]

Randall Vance Dostana song Shatrughan Sinha

[@shanthaperera1938]

Randall Vance ö. Lp

[@aatryayam6375]

Not good

[@ezazahmad4312]

Nice anccal

[@stevethomas211]

I am a beginner at this. It would help me by you talking through of what is being done in the video. And the materials that is being used.

[@GibbonsGroup]

Thanks for reaching out, Steve. We are currently planning on creating some shorter, more instructional videos. This is quite an old video.

[@ToBeDefined85]

@@GibbonsGroup This would be great, I am currently trying to rewind a motor myself.

[@MrTaolaothiendia]

Could you please tell me where I can buy that concentric winding head ?

[@shadrackasmah1285]

Where Sigment 4 DC grinder armature winding were sells and standing fans bushing's

[@churchrapture]

Interesting, but I think heating the stator so hot is not good and sticking something into the slots to scrape so hard is not good.

[@freenergyterminator]

The most important details are not shown, feeding winds in the armature

[@GibbonsGroup]

Hi there, this is by no means a comprehensive guide. Please check out our latest rewinds videos for more info.

[@user-bv4mm6kt3u]

дедок ты красавчик!это факт

[@guillermorodriguez7818]

Which is the machine that is making the groups??

[@englishforbetterlife4826]

Show step by step is more then better for new learners.

[@aryonugroho8711]

Indeed. The title is very not representing the knowledge that are being wanted by viewers of this video.

[@amanatali4674]

Bast motor mastar

[@kavalivinod4504]

Wonderful experienced person Wilding machines are came from the analysis of man mind . For the time saving purpose machines are manufactured. If machines doing winding u don't know how to wind the motor.

[@sundarAKintelart]

Actually he is enjoying his occupation...glad to do what he does...

[@simonpurshouse8636]

I rewind motors don't like seeing a core glowing red like that would think it would cause damage to the laminations.

[@affliction1979]

simon purshouse, exactly. The stator should never be subjected to that sort of heat. A light sand blasting would be more than adequate.

[@rogeronslow1498]

I agree. The silicon steel laminations' magnetic properties ( coercivity and hysteresis) will be altered. Also, each lamination is laquered to electrically insulate it from the one next to it. The heating will damage this insulation. What this guy is doing is sacrelidge.

[@jeremyrjones717]

no they're right

[@rogeronslow1498]

@@DieselRamcharger You never want to take the laminations past their Currie point first off. Also, you don't want to damage the laquer coating if that's what they have. If they rely on the millscale to insulate them then that isn't an issue but the Currie point is and red hot is way above that. The heating after assembly is to drive off moisture and is normally around 120 degC.

[@user-xw9kj2lb3m]

How the connection looks for rewinding electric motor

[@iulian207]

VPI is needed (vacuum pressure impregnation )

[@saruaralam1800]

Sir, do you help me, please?

[@howardtoob]

That's awesome. How long was this process?

[@GibbonsGroup]

24 hours from receipt of the motor to completing the rewind.

[@itcrate]

How to calculate how many to turn required when rewinding.

[@simonreiger7422]

You count the old ones

[@itcrate]

Do not have old wire

[@TheNARF86]

Itcrate yen take it to a rewind shop

[@NMranchhand]

Click bait on the "How TO..." This is a demonstration, but a cool one.

[@hassnakilo5208]

الله يستر عليك

[@charleschancellor3350]

How do you know where to put the wound copper wire when you put it in the moror?

[@GibbonsGroup]

When stripping out the old coils, it's recommended that you make a note, or take pics of how the windings were originally inserted. You'll also need to have the same number of wires in each slot as previous.

[@maryphiri4561]

Hie am not a tech but i want help from here/ i have a 3phase motor 3kw was checking the coils continuity so the 2 coils reads 24 and the 1 reads 35 /am i safe with this motor?

[@jasincolegrove6651]

Mary Phiri the only way to truly know if the insulation has broke down is to check the resistance of the coils when you apply a high voltage.

[@maryphiri4561]

@@jasincolegrove6651 ok thanks

[@MDSUJON-mu9jv]

Wow

[@scania1982]

Aaah, something that is repaired for commercial purposes, rather than replaced.

[@newstoday5091]

Hello brother

[@JoseAntonio-tt2mb]

I Began my life working with rewind motors.

[@morrinahgilbert6708]

What is the connection of 72 slots ,24sets a 240kw motor which is 8 delta

[@47rushing]

Your comment here makes no sense….. I could possibly help though

[@Bedol68]

Dont burning stator to clean the waste varnis,,,it can make the tin of stator email will damage,and touching other part of stator kern.

[@vtechead1]

Sometimes these days it’s cheaper just to buy a new motor.

[@GibbonsGroup]

Absolutely. If we assess a motor and it's more expensive to rewind, we recommend a Gibbons electric motor as a replacement 😉

[@rakeshkewat3362]

Sir AAP kaha se ho

[@paulmonaco1148]

Where in India is this shop??? LOL...

[@Arabia_coffee_shop]

❤️

[@jimmatrix7244]

What paper is inserted into the coil slots?

[@GibbonsGroup]

Hi Jim, our rewinders use Nomex 411 slot insulation. Hope that helps.

[@ucandoit5398]

Why are u heating laminated core

[@nazgullinux6601]

In the way he sets the coils in a helix, eddy current losses are minimized to an extreme. The lamination of the steel plates is for older configurations that are not as efficient. The reason for heating is to make getting rid of old varnish and adhesives so the coils can be installed more easily. The way the coils are set, there is minimal hysteresis loss so magnetic saturation does not occur. Lamination is not required for the configuration used.

[@luuha4310]

*Masyaallah Very Exelent Video But Music Haram*

[@quoclethanh4967]

Does the fire heat damage the steel plate? thanks

[@nazgullinux6601]

No.

[@mohamedabdelkarim8358]

Problem for isolation warnish between laminations

[@XXPomanTradingXX]

the steel plates i believe your referring to is Laminations or iron (at least that is a common term from around my parts/ or what we refer them too.) i dont know everything but from ive been told by our winders that extreme temperatures concentrated on the laminations can cause them to warp and lose their integrity which is a loss of efficiency when/if the motor is completely rewound. for example the 1st motor in the video is WEG stator that has steel Laminations but the outside of stator is cast aluminum. If i were to burn this stator out in an oven, the max temperature of the inside of the oven would need to be less (theoretically) than 660 degress F or the cast aluminum motor surrounding the stator would warp and become useless. the same is applied for the inside of the motor. what was shown on the video in refernce to using propane torches ( from what i can tell) is absolutely acceptable within reason... we can burn out approx 30 of those WEG size motors in about 7 hrs which is more cost effective for us and we have yet had one comeback for and core loss issue. ive only been here 6 years so its defintely possible tho. and for those reading this we burn out the whole motor mainly for cost reasons and also customers lack of knowledge regarding shorted winding usually ends up with roasted windings anyways, so its easier to pull out coils and connections. shits bad for the health tho.

[@elyasbachani7950]

Informative but short video clip

[@MrFlexxip]

how to calculate winding ? based in which formula ?

[@Zapgod]

You look at the motor drawing or when burnt out you pull an example out and count the number of windings

[@superfly8158]

Would this cost more than just buying a new one?

[@GibbonsGroup]

Good question. It all depends on the size of the motor. A small motor such as a 0.18 kW machine wouldn't be worth rewinding, for example. The general rule of thumb is the larger the motor, the more likely that it will be more economical to rewind it rather than replace.

[@spiffdandy77]

steps left out

[@electrichospital4024]

sir, what is name of the varnish

[@GibbonsGroup]

Hello, the varnish used is advanced electrical varnish.

[@electrichospital4024]

@@GibbonsGroup please give me company name of vernish

[@GibbonsGroup]

The company is called AEV limited

[@marcosmatiga3168]

this is only to show & demostrate how to round turn, the magnetic coil. then put the magnetic coil wire into the stator teeh of the motor and the terminal out connection.....but it"s okey!!!!

[@TheElectricProeworkshop]

2800 rpm

[@StewsChannel]

Looks like voodoo to me.

[@GibbonsGroup]

Sometimes our engineers do produce some magic from time to time

[@user-nq5wl5zg3m]

Дедок может и красавчик но железо перегрели , пропитка так не делается гарантии на долговремнную работу никакой

[@Dc_tech386]

I rewinding a motor and it would not start I did everything right

[@Dave_en]

Understand the principle and then apply it on the motor. It requires serious design or simply replicate the old data. If it didn't work, then you have to take it to any motor mechanic and let him find out the actual fault. Troubleshooting requires certain amount of experience.

[@chriscox52282]

Haha. Obviously you didn't.

[@moroofamodu6678]

Is it possible to rewind three phase Generator coil to single phase Generator coil

[@bluesteel7874]

1 phase is less efficient than 3 phase, because there are portions of the rotational movement where power is not generated. To make a 3-phase generator to 1-phase, you just remove two sets of windings. Literally, 3-phase means three 1-phase windings in one housing.

[@omairahaljohani4741]

Electric motors winding technician required to work in saudi arabia

[@lloydmurahwe2191]

What are the contact details

[@danmart1879]

Sorry, but this is NOT an educational video on how to rewind an electric motor, but rather a video about how a motor technician rewinds an electric motor. Nobody would be able to rewire a motor after watching this complex procedure. Good vid, though. Five Stars.

[@stevengarrad4725]

True I've worked in the winding Dept. Of a electric motor company for a decade and we do it a lot more efficient with our methods. Not best example

[@kentrobison588]

It must be slow getting all those wires into the slots without pushing the paper strips down.

[@chedagoz7145]

@@stevengarrad4725 Could you tell me where to learn about modern methods for winding motors? thanks.

[@ishdad9289]

With great respect. But you don't really explain what you are doing .So how must learners learn from you. SIR.

[@GibbonsGroup]

Hi, this wasn't ever really an accurate how-to video as the equations for individual motors would be difficult to explain.

[@mdmamunurrahman4615]

Coil badano slep ring kothiy poji..plz talk to you

[@osaneppenzer8467]

thats lap winding

[@JoseAntonio-tt2mb]

Motor Siemens .

[@matthewkitaszewski4923]

its weg actually

[@JoseAntonio-tt2mb]

@@matthewkitaszewski4923 i m Brazilian ,i know the Weg since 80 th .

[@jahidkhan9158]

Sir aapki age is k lye nahi h रैस्ट kro

[@47rushing]

I mean, can they rewind your motors..??? Yes. Can they rewind them well…??? Kind of… 1: using a torch to burn out the old insulation out of the slots is destroying the laminations. Probably wouldn’t pass a core loss test after that. 2: just pouring the varnish over the winding like that isn’t very good… now with that said, for small non premium efficient motors, you can get away with that probably. But you should really be doing a full dip and bake. Meaning, having a bin full of varnish and completely submerging the motor in the varnish and letting it stay in there anywhere from 15 minutes to an hour depending on motor size. Other than that, the in ding looked really good and it was obviously someone who has wound motors awhile and cares about how it looks.

[@GibbonsGroup]

Hi Bailey, thanks for the detailed comment. After reading your notes and re-watching the video I just wanted to assure you that the motors are submerged in the varnish for every rewind. We have a huge bath full of it that the motors go into before going into the oven. Our social media accounts have a few videos of them coming out if you wanted to check those out. The guys in the workshop have years and years of experience and work on motors every day. But, this video was put together back in 2017 and doesn't show the full extent of what's involved. If you have any other questions about how we do things here, please don't hesitate to ask.

[@hyperflowfans]

I wind my motors with EASA accreditation, core loss & hot spot test, burnout for 10 hours at 700°, take data & strip, media blast, core loss & hot spot test again, stuff, meg ohm & pi test, Dip for an hour, drain, and bake at 350 for 6 hours.

[@allisongardin2096]

Get with IPS !!!!

[@krishankumarsaini744]

1440rpm motor 48 slots 12 sets ex.5 hp I expert in motors winding

[@abasilioss]

where are you located...I want to wind a generator...are u in CA

[@GibbonsGroup]

Hi Adel. No, we are in Essex, UK

[@abasilioss]

@@GibbonsGroup ok Thanks for the reply...I am in California, USA

[@user-rv2bw8by9w]

Do not heat the core it can damage lamination insulation

[@mohamedabdelkarim8358]

It is a bad idea to heat the stator like that ....you'll shrink the warnish between laminations......

[@bigelite4557]

You clearly don’t understand what you are talking about my friend

[@chicken69tenders]

Yeah this definitely looks like a solid stator core motor from a mile away……there cast and then machined to size 🤭

[@sunilkamite2529]

Hp kay ha

[@pintookewat8528]

Sunil kamite 2hptaxmoendaksn

[@jrdelacruz5008]

Peanut

[@hugojauregui5544]

The slow way.....

[@chedagoz7145]

what's the fast way?

[@poserwanabe]

Can anyone say "core loss" Fail 😆😂🤣

[@michaelroberts6299]

How to rewind a motor NO should be rewinding a motor! 7mins of my life ill never get back.

[@dennisdoran6988]

Sorry to say but rewinding motors is not for the untrained or ill equipped. There are a lot of things that you see in this video but you dont know how they were arrived at. And no the video does not explain it. also, you definitely do not have access to the machinery required to do this. That said, if you want to do an apprenticeship in motor winding and live in Australia, I have three positions vacant for first year apprentices.

[@michaelroberts6299]

@@dennisdoran6988 Thats good to know thankyou but im not sure what it has to do with the tittle. All the best mate.

[@chriscox52282]

@@michaelroberts6299ignorance. Do you think they could fit that kind of instruction in a 7 minute video? If so, maybe you should stop being such an ass and learn some things.

[@michaelroberts6299]

@@chriscox52282 no i dont think it could be learnt in a 7 minute video whats your piont?

[@GibbonsGroup]

We're sorry that you felt this was a waste of time and yes, also understand that this is not a detailed instruction video of the rewinding process from start to finish. However, we are hoping to release a more detailed video in the future.

[@HmongGuitarPlayer]

When you start to clean the slots with a torch and turn the laminations tooth red hot I know you are not a very qualified winder that know very little about core loss in stator. The rest is good.

[@hhhbkid]

Oh my goodness... did they have to show a different stator because the first one got ruined when they put the torch on it? Wow, oh wow. I wouldn't have cold-stripped it either. Don't you have a burn oven? Or a torch? Smh.

[@paulmonaco1148]

Funny only another motor WINDER would notice the two different stators. hahahahahahahaha. Really OLD school, you aren't going to cold strip an EPOXY dipped stator. LOL. I was going to write " Where in Romania is this shop " ??? Hahahahaha I have rewound over 10,000 stators, mostly under 100-HP in a nearly 40 yr career and I still enjoy watching how different shops wind their stators. Even at my old dinosaur age, i could stuff these slots with the youngsters, if my hands didn't go bad on me. I would still be winding. LOL.

[@hhhbkid]

@@paulmonaco1148 The fins on those aluminum frame jobs ALWAYS stick out to me. Then I noticed the number of slots was way off too, lol. The first one was like 36 and the second was almost 72.

[@shivajisuryavanshi1705]

Connection a1à2b1b2c1c2 not clear understand

[@carlospereda100]

It is not recommended to rewind a motor, because the static part loses the inductance and that generates more energy consumption and low performance, in one year of consumption it will recharge more than 20% of cost in your electric billing

[@chedagoz7145]

Why does it lose inductance? where can I learn more about this?

[@zadvindersingh4234]

Please explain about that thank you.

[@bluesteel7874]

The static parts of a motor is more relevant to its magnetic permeability. This may affect inductance. But the large portion of the inductance is in the coil. Shorts in the coil will decrease inductance. I do not think that decrease in permeability of the core will be large enough to equate to a twenty percent increase in power cost. If the motor is rewounded to the same specs, the consumption should be around the same.

[@nazgullinux6601]

Carlos you have no idea what you are talking about. The coils he wound are wound according to the plate on the motor case. The inductance will be nearly the same if not identical. You don't have a clue about inductance if you are serious.

[@dennisdoran6988]

Not true, we actually find with older motors that they perform far better than factory due to improvements in the materials and techniques.

[@adegboyegaemmanuel8893]

I watesd my time and data downloading, not educative..

[@GibbonsGroup]

This is by no means a comprehensive and detailed video of the motor winding process. We are sorry you wasted your time and data.