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Processes
The following information describes the basic manufacturing steps and processes used by Windings to produce stators and rotors. These processes can be customized as necessary to meet customer requirements.
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Lamination Bonding
Steel lamination are cleaned, aligned, coated with 3M™ Scotchcast™ 265 Powder Epoxy Coating (or customer specified material), and heat cured to form bonded stack assemblies. Custom-made tools and fixtures provide alignment per design specifications. The stack assemblies are then either shipped to the customer or moved on for further in-plant processing.
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Insulating
Insulation is provided in multiple forms. Epoxy coatings, including 3M™ Scotchcast™ Powder Epoxy Coatings (260, 262, 5555), typically ranging from 0.008 to 0.012 inches thickness, are applied with a fluidized bed process and heat cured. Dupont Nomex® or other slot lining materials are available for high temperature and other stringent applications.
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Winding
Magnet wire of the specified type and size is wound on custom precision chucks to produce coils of the correct diameter. When possible, coils are wound in series to eliminate interconnections. In some special applications magnet wire is wound in-place over the insulated lamination stack.
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Coil Placement
The wound coils are inserted into the insulated slots of the stack. Specialized techniques are used to minimize coil size and thereby attain lower resistance values, and shorter end turns. When specified, insulation is also placed between coil phases within the slots and/or within the coil end-turns.
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Finishing Coil End Turns
The bottom end-turns (non-lead-end) are usually laced to form a neat package without loose strands of magnet wire coils. Lead wires of the specified type, size, and length are connected to the magnet wire coils using high temperature solder. Brazing is also an available method. Lead connections are then laced into the top end-turns (lead end) to hold them securely in place. Using a press and a specially made forming fixture, the magnet wire coils are formed (compressed) into their required dimensions.
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Varnishing
The varnish operation utilizes customer specified materials and processes. Facilities are available for Vacuum Pressure Impregnation (VPI), submersion, trickle down, and heat curing techniques. Stator assemblies can be encapsulated, as an addition or alternative to varnishing, with Customer specified potting materials.
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Machining
Precise machining of stack surfaces is available. Stacks can be ground (outside diameter), honed (inside diameter), turned, and milled to meet to meet the needed dimensions and features. Tolerances of ± 0.0001 inches can be maintained.
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Electrical Testing and Final Inspection
Every unit undergoes a Quality Assurance review. High potential voltage, surge, resistance, inductance, and other electrical tests are performed as necessary to assure conformance to Customer specifications. Test results are electronically recorded and stored for future analysis. If requested, test results may accompany product shipments.
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