How to wind the DC brushed motor windings and coils

How to wind the DC brush motor windings

There are two commonly used winding methods for brushed DC motors: lap winding and wave winding.

Lap Winding

Lap winding, also known as parallel winding, means that all coils of the winding are connected together. When current flows through each coil, a magnetic field will be generated between adjacent coils. The magnetic field direction is the same, and finally a total magnetic field is formed. In Lap winding, current can pass through the coil in any direction, so the motor can be rotated in any direction. Lap winding is often used in low-power, low-speed and high-torque motors.

Wave Winding

Wave winding, also known as series winding, means that the coils are connected in series, the current in each coil is the same, and the magnetic field is in the same direction. The motor with wave winding is more stable at high speed, but there will be a larger starting current at low speed and high torque. Wave winding is often used in high-power, high-speed and low-torque motors.

It should be noted that when winding the motor, it is necessary to select the appropriate winding method according to the specific use requirements and motor parameters, and ensure that the quality and insulation performance of the winding meet the requirements to ensure the normal operation and service life of the motor. If you are not sure how to wind the motor, it is recommended to seek help from professional technicians.

DC brush motor coil winding method

There are two ways to wind the coil of a brushed DC motor: manual winding and machine winding. The following is the manual winding method:

Preparation

First, you need to determine the number of coils required, the wire diameter of the coils, and the details of the winding. Choose the appropriate core and magnet to install the winding, and ensure that the size of the winding coil and the gap size after winding can adapt to the installation conditions.

Winding

Wind the wire into a coil on the iron core. The number and shape of the coils should be determined according to the needs of the motor. Fix the end of the wire on the coil and cut off the excess wire length.

Connect the coil

Connect the wire at the end of the coil to the motor through the brush to complete the connection of the coil. When connecting, pay attention to the connection sequence and insulation performance of the wires.

Test coil

Test the resistance, inductance and insulation performance of the coil to see if they meet the requirements. You can use a multimeter, inductance meter and other testing instruments for the test.

Machine winding can automatically wind the coil and improve production efficiency. You need to set the machine parameters in advance and choose the appropriate wire diameter and number of coils.

It should be noted that the coil winding needs to be selected according to the specific motor parameters and usage requirements. The quality and insulation performance of the coil directly affect the performance and life of the motor, so high-quality wires and insulation materials should be used as much as possible, and the operating specifications should be paid attention to during the winding process to ensure that the coil quality and insulation performance meet the requirements.