Electric Motor Resource Center

What Are Winding Assemblies?

Winding assemblies refer to the configuration of coiled materials within a motor’s stator. The motor’s performance, operation, and potential to endure certain conditions, will depend greatly on these materials as well as how they are arranged. In their most basic capacity, stator winding assemblies can be used to modify the conductivity within the stator and rotor assembly, thereby affecting how the electric motor runs. 

Winding assemblies can sometimes refer to the complete stator assembly, which includes the windings and/or potting and, in the case of an AC motor, the stationary coil and core. It can also be a way of referring to any wound component within a motion control device, including the bobbin wound coils, self-supporting coils, rotor windings, and other parts.   

How Are Winding Assemblies Made?

The manufacturer of winding assemblies can vary based on the specific type of motion control device and its performance requirements. There are many different types of stator winding assemblies, which can include skein wound and hand-inserted styles, potted coils, symmetrical insertion, wave insertion, lap winding, concentric winding, and more. 

The wire used in these windings is made of a conductive material, such as copper, iron, and aluminum. Special tooling and techniques are used to create laminations, which are layers of the material. The laminations will contribute to certain levels of conductivity, which then facilitates certain performance capacities. The ends of these wire coils are connected to lead wires.

The assembly is then compressed to reduce resistance and improve end turns. Insulation may also be incorporated into the windings to enhance the endurance of the device. Once the laminations are completed, insulated, and cleaned, they are then cured and bonded or welded.

The winding assembly is then incorporated into the stator and rotor, which is then used to manufacture the motor. Sometimes the winding assembly or stator and rotor kit is packaged and sold as components to OEMs. 

How Do Winding Assemblies Affect Motor Performance?

Winding assemblies have a big impact on the performance and endurance of a motor. Stator windings will generate the magnetic field that makes the rotor spin, therefore the components and configurations that form this element will greatly contribute to a motor’s operation.

Additions such as winding insulation, high-temperature magnet wire, coil potting, sealing, and other customizations can be used to enhance the performance of the motor and improve its endurance. 

Individual electric motor manufacturers may use their own specialized winding assembly tools and techniques to achieve unique performance parameters.

The coil winding assembly within the motor, and other components such as the motor’s housing, can be the difference between a standard-duty motor and a high-performance motor that can operate in extremely demanding conditions.    

Where To Get Custom Coil Winding Assemblies?

Custom coil winding assemblies typically must be sourced from a dedicated motion control or electric motor manufacturer, although not all manufacturers will provide stator windings or stator and rotor kits that are separate from the motor.

A stator winding assemblies manufacturer will customize these parts by offering a different selection of magnet wires, winding types, insulation, potting, and other elements. 

Capabilities that are integral to custom winding assemblies including vacuum grinding, honing, the manufacture of potted coils, and the use of specialized coiling and stacking tools. 

Coil winding manufacturers may also utilize their own special combination of materials to achieve certain conductivity and high-performance specifications.