Ivan's Garage

Hand Winding 3 Phase Motor for Electric Vehicle (Part One)

[@stephenmedeiros499]

Hey Ivan!! That was a totally different way of re winding I've never seen before. The way I was taught is through groups and whatnot. I'm glad to have seen a different version and honestly miss rewinding and working on motors in general. Thanks!!

[@Ivansgarage]

I use to rewind, in a motor shop, you would wind each pole and then lay it up, correct? but would only have 3 or 4 20 gauge in hand, so the pole connections where no big deal..... When ya start winding 12, 18 gauge in hand the pole connections are way to big to all fit in case, you would have 9 extra connections, 3 on each phase times 3 phases, never fit in end bells.... I could wind a motor quicker with all in-hand laying each phase one at a time, and way less connections...

[@stephenmedeiros499]

@@Ivansgarage I wasn't really taught by poles and it's been over 10 years since I've touched a motor lol

[@douglasanderson1151]

I love full Metal Jacket. what a awesome interrupted piece of the video!

[@e.edgarbruce6613]

Very interesting and varied field of work this - repair and maintenance of rotating electrical machiners, ac or dc, motor/generator, and winding design, construction and installation. Good, very clear video.

[@nohchogums]

Excellent work ! Looks perfect!

[@Twinflower]

Thank you very much for this video! It was very intuitive and it was for perfect for me to finally complete my understanding on how the poles are actually arranged. Keep it up!

[@volleyballjerry]

Ivan - this is pretty remarkable work and a great video. I always wanted to understand how motors work and how to take them apart. Outstanding work! Also appreciate the use of a camera tripod to keep the shot steady. Very cool!

[@narendergodara1992]

amazing Technique for winding 💕💕💕💕💕

[@GREEnT704]

"HOW TALL ARE YOU PRIVATE?!" lol I thought that was in another tab on my end. Great video by the way.

Thanks for the video Ivan, very educational.

[@benkiluv]

great ...i was really looking for this to clear my doubt..and only this old method of winding could clear this doubt.

[@anikroy7151]

Thank you for making my doubts cleared

[@robviolin1]

Thank you for your great information. Great video. 👍

[@Ivansgarage]

I first take bailling wire and lay the first pole, add 1 foot to each end, times four for four poles and that is the lenth of my wire for 1 phase.

[@basyoni95]

thank you so much sir for making these videos, it really helps :)

[@alexmaximas384]

Thank you very much for sharing.

[@jonyjbara3763]

eres super procesional Me encanta su vídeo..!

[@SunilSundar]

Why do you have to leave so much wire sticking out the ends? why cant you wrap it much tighter?

[@akshaykumarvyas]

hi evan. can you please tell me how you calculated the parameters of the motor like no. of wires per slot.,, no. of poles.,, diameter of the stator,, , length of the stator, etc. any books or links that you could suggest for motor design or could you do a tutorial on motor design. please. dying to know how these beauties are designed and constructed. thank you

[@joew1865]

Wow...thank you for sharing!

[@georgesiatos9848]

great video!

[@danm2088]

I have a dumb question, how did you get the old windings out? the stator body doesn't look like you cooked it. and I can see old varnish drippings above the top end (view in video) which means its not a new stator. every time I had to cut winding crowns out we had to burn it first which miscolored everything but that one looks perfect.

[@ivanbennett383]

I use a wire brush and drill to cleanup the stator and housing, then spray the stator and housing with spray varnish, insulator.

[@8j6lyWotvmcD50Q8rgEW]

Sound advice. Good practice.

[@Ivansgarage]

I buy all my motor supplies from a motor shop, insulation paper, phase insulation, slot sticks and magnet wire.

[@Caution16]

Ivansgarage hi sir!, can you please tell me how to find the terminal on that winding? please

[@chrispewpew]

+Ivansgarage How much did this build cost you?

[@shigatsuningen]

Great educational video which covers the gap from many others I have seen on KZbin. I do however second the question from Jolan Olea here. How does one find winding diagrams and how does one determine the number of wires in a coil? A short how-to on finding this information and we'll be set to do our own, short of counting inside of an original motor.

[@chrissorrells427]

So you got a 1 turn 24 wire in hand motor wound in the skeem wound configuration.1-7pitch with a total of 12 groups of 3 coil per group lap wound correct.this is a 4 pole motor about 1800 rpm.You could probably recalculate that and have it to where you can pre-fabricate the coils ahead of time with more circuit and wire in hand but you going to need a program to run all your density to match you original density so it's better the way you do it. Nice job.

[@paulmonaco1148]

chris : On a golf cart motor??? 1 turn 24 in hand, hardly seems doable. LOL...

[@aurangozebalam5012]

Good job

[@perceive8159]

Thanks for the vid. Had a?. I put together 3phase 220v AC roto phase converters 15HP and up. Now I read that if you rewound the motor so to stabilize the voltage on one leg namely #3 with more wire It will keep the voltage of 120v AC on that leg and not drop under load which does happen on converters quite a bit. I balance with caps but that changes under the workload applied to the motor. As you add more caps on the different legs it shifts the balance of the phases this way or that, never giving you a true 120 degree between the phases. So can this be done? I would like to try it on a say 10HP

[@santopietropaolo]

good job.

[@bpiper122]

Thank you! This video helped me too!

[@davidmiller5832]

Haha. I just finished watching Full Metal Jacket this evening.

[@danerovz2796]

mr ivan i want to ask if it is the same diagram even in 72 winding slot??? thank

[@thebuggy736]

Hi Ivan could you please give me a link to the winding schema. this is the print you use in your video.Thank you.

[@Ivansgarage]

+thebuggy73 This is for a 36 slot stator motor all windings for a Curtis Controller should be 3 turns, 8 inhand, 18 gauge mag wire. Each phase lead (delta) would be 16, 18 gauge wires, think that will handle some current, how about 125 amps continuous and 650 amps peak... Now we are talking 225 foot lbs of torque out of a original 10 hp motor... ivanbennett.com/ev-motorwinding.html

[@adnanalmactoom6475]

good job man

[@inventoseideas3400]

Hi Ivan what store i can find everything for repair motors like copper wire coil, insulation etc.etc. thanks

[@amalfrancis9683]

hi i need your some help to rewind my drainer motor 240 v ac 50 hz 4.0 uf can you pls help me out

[@Ivansgarage]

What wires are you talking about, the ends? once they are all layed they are tied very tight with tie cord.

[@sidhiquemanammal8087]

thank you. This vedeo cleared my doubt

[@juancantu6884]

about how much copper wiring those it take to finish winding this engine (in lbs)

[@Ivansgarage]

+Juan Cantu It takes about 12 lbs of mag wire per motor.

[@tonverma543]

Sir this type of winding is done only on rare case, because only series connection is done on this method

[@Pit315689]

Hi Ivan, two questions from someone who does not know much about electric motors/generators, but trying to understand.... 1. Is each individual strand of copper wire insulated from the next ? i.e. so current travels only along the length of the copper wire and not across a bunch of wires....? i.e. is each strand of individual wire dipped in some insulating 'stuff' ? 2.I notice in your video the same length of copper wire is used for each Pole, i.e. there is no cutting of the wire when you have wound the first Pole, you just keep winding into the next Pole - so what is it that gives the North/South change....is it the direction of wind ? is this reversed so current is now flowing in the opposite direction ? Thanks

[@ivanbennett383]

Yes each wire is coated with varnish (its magnet wire} google it. This is why I hand wind, pole to pole, so there is no pole to pole connections, they would be to large. North/South pole change comes from AC, alternating current.These are all 3-phase AC motors.

[@Pit315689]

cool, thanks for your info and advice.

[@wanatuik3147]

How many HP of this motor, sir?

[@geneallgaier9550]

How much wire did you use for that job? Ball park a cost today? (for something similar)

[@Ivansgarage]

+Gene Allgaier 12 lbs of mag wire, so two rolls of 18 gauge. about 200 dollars just for the wire .... here is link www.temcoindustrialpower.com/products/Magnet_Wire/MW0154.html

[@geneallgaier9550]

Thanks Ivan...

[@Wizowes95]

Have you got any advice on how to shape each coil. I work in a rewinds factory and machine wind the coils. But I can never get the end windings to look neat.

[@danm2088]

I don't know the setup you have, but the shop I worked at had a welded adjustable rack, when we were done with a set of coils we just tighted up the rack until the coil was nice and square (or whatever shape usually ours were like a long hexagon) . using a small layer of Teflon tape to keep them together. but this guy in this video is doing it way differently. so idk,

[@ivanbennett383]

practice makes perfect, you really don't need to square up the winding unless you need the head room.

[@Ozziepeck11]

@manuel alfaro for copper wire, try maplin or radio shack, i tend to use either radio shack or eBay, if its repairing the motor, most of it can be bought on eBay, if not then phone up maplin, hope this was helpful.

[@dsanmig22]

how can you know if you're coil length is correct doing it that way??

[@wanatuik3147]

What is curtis controller Sir? Is it can upgrade HP?

[@gona8371]

hello sr. i need to rewind ac motor but. all motors in my area have not correct copper wire size and number of copper wire in a slot. please if you can send me all motor data book which explain about copper size and number of copper wire per slot in ever induction motor. i am waiting you

[@urdulearner8221]

+Ebrahim Mohammed Hello , did you find anything useful ? If you find send me please . Thanks

[@ivanbennett383]

I use a piece of wire old wire left over and lay the first pole, remove it and measure it, times 4, for 4 poles, thats the length for one phase lay. On that test lay on the first pole I leave at least a foot out each end. Ya don't want to be to short. Winding for the Curtis Controller I try to use 12 inhand and 2 turns,..so 24 wires for the first lay..first phase....double layer-second phase = 48 wires per slot.... Yes you use magnet wire to wind a motor. I all ways use 18 gauge. This is the wire I have been using. It takes about 12 lbs. per motor. 2 rolls. This is the link where I buy my wire.... www.temcoindustrialpower.com/products/Magnet_Wire/MW0154.html Ivan

[@hardcooling]

hi there I work on refrigeration and other machines I always wanted to do your type of work but never could get the time to go learn it wish I did : ) oh yeah would you be able to tell me how to calculate what size start cap and run cap I would need for an X size single phase motor thanks

[@nareshnamanaresh]

I didn't get that type of diagram!plz give me detailed diagram like each coil connection

[@pingchingcheung935]

Hello sir, are those wires insulated?

[@monsterjesse332]

Hey nice video I subscribe.a question if u could. But I was just reading.... To help reduce current heat Shouldnt the wires be wound as tight as possible ?

[@DieSirenenwerkstatt]

hello. Great video but i have one Question: Where can i get the insulation material you used?

[@Texaca]

how do you know how much wire to use, it looks like it was pre-cut, to the exact number of strands, and length. But How do you know, exactly how much wire will be used inside for all the windings. Obviously you have to know a ballpark figure as to how much you need, or else you would get to the end and be short... D'Oh... Is this magnetic wire, or just regular coated copper wire...?

[@lailatsleb2246]

،

[@melbose]

Holy fuck this must be old old school; what a pain in the ass to wind a motor a pro winder winds his coils seperatly that is one pain in the ass u wind it mate

[@MichaelChismToday]

Hello ;) where did you purchase your slot sticks?? Thanks MIke ;)

[@tdneVmo]

Thank you!

[@JoseAntonio-tt2mb]

Dont you have form for to make Wind?

[@Ivansgarage]

You can't wind a whole phase on a form, most form winding is done a pole at a time, then you would have three connections per phase 9 connections in all for the 3 phases, big connections, to big to fit in motor... make sense... that is why I lay each phase one at a time then you only have 3 connections for the leads out of the motor...

[@ivanbennett383]

The biggest reason for laying coils all in hand is there is NO pole connections. For each phase you would have 3 large pole connections (9 total) plus your delta connections, if you did a lap winding..That is why I do basket weave winding. No pole connections.

[@melbose]

sorry mate you are refering to phases so you did 9 coil so it is 9 groups of maybe 3 coilsg for a 6 pole consequent so start to finish which you did by your wiring for a conventional winding of 28 groups of what ever coils you need to so start to start or finish to finish where you can not do how you have wound that motor.

[@ivanbennett383]

Don't know what you are talking about. Simple, Lets talk 1 phase, There is 3 coils per pole 4 poles per phase evenly distributed around the stator, four pole motor. Each pole uses 9 slots. I can lay by hand each phase in 45 minute.

[@chrismelcher1528]

+Aaron Melbourne ; You claim to be a winder, but I can't find any of your videos. I wonder how you could find the time to wind Motors when you spend so much time bashing an old man. At least he is willing to volunteer his time and knowledge in hope of helping someone. You may ask yourself ' who am I to be speaking on this subject ??'. Well I am an electrical service tech. I can wind, balance, surge, hi-pot, load test, and install an Electric Motor. I also laser align, do vibration analysis, size & install AC drives, starters, contacts, & phase inverter's. Along with PM DC's in place or in the shop. I obviously don't need info from this man but I appreciate his willingness to help others and pass along information. if only more people would do the same......

[@Ivansgarage]

Really don't understand, there is 8 vids on winding and the forum. ivanbennett.com/forum/index.php this forum is two years of research and posting all for FREE

[@chrismelcher1528]

Thanks for your time and effort.

[@topgearIQ]

hi.are you rewinding motor two speed single phase..diagram circuit coil.thanks

[@Ivansgarage]

No these motors are wound for 50Volts and used with a curtis controller, variable speed.

[@topgearIQ]

+Ivansgarage theses motor two speed high and low. work to 220v 2.5ampers..motor water colding. thanks for message.mohammed from Iraq.

[@alikrasniqikrasniqu1228]

Ivansgarage

[@alikrasniqikrasniqu1228]

Ivansgarage

[@alikrasniqikrasniqu1228]

Top Gear

[@imehokon1690]

coils are hard generally. what makes them hard?

[@paulmonaco1148]

The circular mil is the determining factor. To make a winding easier to rewind we often reduce the cir. mil. You can take data that needs to be 1 # 15 AWG and reduce to 2# 18's AWG use the same turns. B-U-T If you are short on a wire supply and need to figure out the best way to use the supply available. This will work. Say your ORIGINAL DATA is 6# 16 AWG 7 turns and a (1) WYE 460 volt connection. In a formula that is know as ( Cut the wire size in half, then double the turns and double the connection. ) You would then be able to use NEW DATA 6# 19's AWG 14 turns and (2) WYE connection. This will N-O-T work if your final voltage is 230 volts. SORRY.

[@tamkamarevo1831]

I was a repairman 2,4,6,8,10 Pole

[@switchkwb]

Ivan it would be 10 times faster if you use preformed coils. Make the coils up 1st then place them.

[@Ivansgarage]

You can not use preformed coils, You would have four coil sets per pole and 3 more connections per phase for a total of twelve LARGE connections. There is no way they would fit in the motor bells, end frames. A regular motor may have 3 wires in hand for each pole with a six wire connection, I use 12 wires for each pole there is a 24 wire connection for each pole. There is no way you can pre-form a whole phase then lay it in because, every other pole has a longer jump in slots than the previous one. Make sense? Time wise, by the time you wind one coil set (one pole) 4 coil sets per phase then do the extra connections (3) for each of the four poles, one phase, I can lay the whole phase faster, with no pole connections, 1 hour to lay a phase.

[@michaeljennings5170]

you dont connect each wire you tie them together for the connection

[@switchkwb]

Hi Ivan. You would use a small fibre board 'scraper' to assist in inserting the coils if they are preformed. Those slot tops are open enough to wind this a standard method but everyone to their own method I guess. I've wound from 0.37kw to 900kw motors for the past 35 years so I thought my input may have save you some time. Sorry I didn't mean to sound condescending at all. Thanks for the vids by the way. :)

[@Ivansgarage]

Yes, I use a couple of different plastic tools to slide through the slot while feeding the coils.

[@robertatwood2503]

switchkwb with all your experience I would like to see a video because in my ignorance I thought this dude was doing a good job

[@2LZA3EEM]

I thought the order is ABCABCABC for every slot.. but this shape alitle bit5 different ... or i did get it

[@Ivansgarage]

Really does not matter What you label each phase ABC, CBA They are all the same, the biggest part is the (start) (finish) of every phase, all three phases are the same true? A start A finish .... B Start B Finish ...... ect I usually put a tag-tape when I start a winding (phase) AS for A-Start then once the phase is layed AF A-Finish ect.... on with the next phase ......

[@melbose]

Wow mate you are making it look so hard youy can wind your coils on a electric machine and insertion al lot easier than what you are doing mate

[@ivanbennett383]

This is DIY, NOT a Baldor factory.

[@melbose]

Ivansgarage Well mate we are not a so called Baldor factory either we repair all motors no matter what make

[@jackbramwell5208]

Ivansgarage Spot-on Ivan. As a builder, I might have to repair or replace a motor once every few years. So I dont want to invest in special winders etc. I need to know the theory and the method. You say 3 winds per slot. Most motors have lots more than that dont they?

[@ivanbennett383]

Jack Bramwell That all depends on the motor voltage you want, the best way is to see what the original wind is. I only wind motors for the Curtis Controller, 50-70 volt and 650 amps..

[@skaterfugater]

I am right with the assumption that the disadvantage of single pre-prepared coils (if you can call it a disadvantage) is that the coils need to be connected in the end by soldering correct wires together? Because the approach shown here has one long line of copper going a long way rather than separate coils. isnt that an advantage? thanks in advance

[@JoseAntonio-tt2mb]

Good morning ,is it motor 4 poles ?

[@Ivansgarage]

Yes 4 poles ... 3 phase

[@JoseAntonio-tt2mb]

@@Ivansgarage are you rewinding all types of motors?

[@Ivansgarage]

@@JoseAntonio-tt2mb NO don't do motors any more....

[@jameskinuthia7605]

How many poles does this motor has?

[@paulmonaco1148]

james kinuthia : In the OLD days there was easy formula : Poles times phase equal grouping. EXAMPLE (4) pole winding X 3 phase = 12 groups. Then you divide the groups by the number of slots. 36 slot divide by 12 groups = 3. So you wind 12 groups of 3. If you had a 48 slot motor divided by 12 group = 4 The poles go( 2 )pole = 3600 rpm (4) pole = 1800 rpm, (6) pole = 1200 rpm, (8) pole 900 rpm, (10) pole 720 rpm (12) pole 600 rpm, (14) 540 rpm Standard slot configurations are 24 -36 - 48 - 54 - 60 - 72 slots. More RARE are 12 slot 18 slot and above 96 slot even 42. Different slot numbers DON't always come out equal to a said rpm. That's were you hear the term ODD GROUPINGS. If you had a 1200 rpm winding in a 54 slot stator, that would be 18 groups of 3, but if you had that same 1200 rpm winding in 48 slots. That's were you get ODD GROUPS. I know it's confusing, but I did it for 38-yrs so it all makes perfect sense to me LOL...

[@gowsankar215]

whats difference between star connection and delta connection

[@Ivansgarage]

Here is nice diagrams, Delta or wye connecting. ivanbennett.com/forum/index.php?topic=26.0

[@Nick-jh4ju]

+Gowrisankar Gowrisankar star draws less starting current which is good on big loads as you dont want to blow your leads off

[@Ivansgarage]

+nicholas piacentini Less current, all so means less torque, 20-30% less. That is why I all ways do a delta connection. I use 2-0 leads able to handle 650 amps.. You won't blow those.

[@Nick-jh4ju]

When you have big motors (550KW) you dont do an internal connection so people can choose how they want the configuration from the terminal board

[@nikolaradakovic5050]

Ivan, is this sinusoidal winding?

[@Ivansgarage]

I guess one could call it that sinusoidally distributed windings whose axes are displaced by 120 degrees apart, I call it balanced winding, evenly distributed. With a regular overlap winding running on three phase the phases coming in are never equal most of the time a wild leg will exist, but using a controller all legs are equal, so the reason for the balanced winding and less saturation for a group of slots. You asked.

[@kevincoates4584]

Why are you scan winding it would be easer to wind the coil groups

[@ivanbennett383]

If you where to do pole groups you would have 3 pole connections for each phase times 3 phases = 9 (24 wire connections) plus you would have your 3 delta connections. To much of a cluster to fit in the motor. It only takes me about 1 hour max to lay each phase and no pole connections.

[@michaeljennings5170]

you can make a connetion just as tight as the coil with little room expansion very easy

[@PawanKumar-xi9qu]

I am want to do work the motor repairing in you're shop you can give me one chance

[@Ozziepeck11]

isn't it annoying to find a particular video if there all called Ivan's Garage? good vid though,

[@jolandic]

Full metal jacjet?

[@dsanmig22]

wind the coil separately then insert it in the slots.

[@Technology-kx3fg]

thanks you

[@vubuihoang8597]

Đây là máy phát điện hã chú

[@primaryelectricpowerllc7230]

Absolutely it!

[@otrotland5377]

wow, dose anyone rewind motors any more

[@Ivansgarage]

Of coarse they do, a lot of specialty motors are cheaper to get rewound than buying a new one... where are you at, google motor shops, rewinding....

[@otrotland5377]

@@Ivansgarage opelika, alabama

[@pantera607]

VERY SLOW,GOOD VIDEO.

[@abumasud7092]

I appreciate your useful action. someone like is honored in ISLAM

[@michealjoseph2224]

I want to rewind 3.5 generator stator pls send me d connection

[@arsenioegoytorogiguinat2826]

wow this is what i am looking for, step by step tutorial and easy to understand but where is part two ?

[@Ivansgarage]

The second phase would start 60 degrees around from the first phase and third phase same thing. If the stator has 36 slots each slot would be 10 degrees. Allways make sure you are winding in the same direction all three phases. I wind counter clockwise, start on the bottom and go right. Turning the motor in a clockwize direction.

[@dubledeuce875]

Another example of someone telling me everything HE knows about it and nothing that I need to know. He would be better off on a stage somewhere doing vaudeville.

[@ivanbennett383]

Well, what do you need to know?

[@recardoromeral7843]

ser how to rewind a 6 pole..

[@iskandarmegat112]

Formula turn and size cable share

[@nareshnamanaresh]

plz tell me about connections

[@Ivansgarage]

Read this ivanbennett.com/forum/index.php?topic=26.0

[@steevenordonez4756]

Ivansgarage

[@naumsilva6984]

Hi Friend, I saw your video is very good but does not need all the time is showing this drawing, already know, this is a step lock 7 serial link 220/440 engine meresponda ok if you want

[@user-tw2jc7er7v]

Δεν μπορεί εσύ με τον τρόπο που δουλεύεις να είσαι περιεληκτής !!

[@phiphatpongpimboon4941]

ผมยากพันแบบนี้เป็นบ้าง

[@JoseAntonio-tt2mb]

I m winder eléctrician.

[@nareshnamanaresh]

if Ur able to upload video plz do!

[@PawanKumar-xi9qu]

Because I am worker of motor mechanics

[@jacoboduor2298]

Am interested but you block everything

[@Ivansgarage]

Block what I don't understand?

[@remmorabaya130]

Not finished

[@alexeggers6475]

this is a waste of time, the coils should be made in advance there is plenty of room to connect the winding

[@Ivansgarage]

If you know all about this why are you here?

[@alexeggers6475]

because i was bored

[@Ivansgarage]

I can understand that, believe me LOL

[@michaeljennings5170]

you are taking to much time i can make the coils and wind this motor and connect in about two hours and for best results not to get wire between paper and slot is to paint the stator white.

[@sajjadmd9642]

plz in hindi speak

[@nippon2003]

Are you serious?

[@ci3619]

I first take bailling wire and lay the first pole, add 1 foot to each end, times four for four poles and that is the lenth of my wire for 1 phase.

[@jameskinuthia7605]

How many poles does this motor has?

[@Ivansgarage]

Four poles only wind for four poles with a Curtis Controler

[@jameskinuthia7605]

Ok, thanks