How to rewind an electric motor from start to finish

Introduction

Rewinding an electric motor is a meticulous process that involves replacing the original windings with new ones. This tutorial will guide you through the essential steps to successfully rewind an electric motor, providing practical tips and insights along the way. Keep in mind that variations exist based on different motor types and winding patterns.

Step 1: Disassemble the Motor

• Remove the motor from its housing: Use the appropriate tools to unscrew and detach the motor from its mounting.
• Take note of the assembly: Document the layout and connections of the motor components to facilitate reassembly.
• Open the motor casing: Carefully unscrew and lift off the casing to expose the stator or armature.

Step 2: Cut Out Original Windings

• Identify the winding connections: Use a multimeter to find the starting and ending points of the windings.
• Cut the windings: Use a wire cutter to carefully remove the old windings from the stator or armature. Avoid damaging other components.
• Clean the core: Remove any debris or insulation remnants from the core to prepare for new windings.

Step 3: Prepare New Wire

• Select the correct wire gauge: Ensure the new winding wire matches the original gauge and type. This is crucial for maintaining motor performance.
• Measure the required length: Estimate the length of wire needed for the windings based on the original configuration.

Step 4: Wind the New Coils

• Start winding: Anchor the new wire to the core and begin making coils.
  • Ensure each coil is tight and evenly spaced.
  • Follow the winding pattern of the original motor for accurate performance.
• Secure the coils: Use insulating tape or similar materials to hold the coils in place.

Step 5: Connect the Windings

• Attach the wire ends: Connect the new wire ends to the designated terminals on the motor.
• Check connections: Use a multimeter to verify the continuity and integrity of the connections.

Step 6: Reassemble the Motor

• Reapply insulation: Use insulation materials to cover exposed wires and prevent short circuits.
• Reattach the casing: Align and secure the motor casing back to its original position.
• Mount the motor: Reinstall the motor in its housing, ensuring all connections are tight and secure.

Conclusion

Rewinding an electric motor requires precision and attention to detail. By following these steps, you can effectively replace old windings and restore motor functionality. If you're unsure about any step or need further assistance, consider reaching out to professionals like Gibbons Engineering Group for expert guidance. Happy rewinding!