Brilliant motor rewinding

[fizzy]

Found this fascinating to watch.

I think Parm said his family do something similar?

 

[Pete.]

I would have got my wrist slapped for not using protectors on the slot openings to save scraping varnish off the wire. Those guys are working a lot faster than I ever did though, mind you the motors I wound you could usually pick up a couple or three in your hand

 

[graffian]

I have a coil to rewind, it was the wrong voltage and rather than doing anything I watched some you tube vids.

One I liked, another indian one, he's rewinding the mag coils on a little yamaha. Vid starts with no
spark and ends with him revving the nuts off the bike. When he cut the coils off you can see it was a
backyard rewind, so I am guessing they don't give a long guarantee.

 

[eddie49]

Somewhere I have a sheet of the "paper" insulation, grey in colour - presspahn I think it was called.

Here's a pic of a scary stack of some big motors:

 

[pedrobedro]

I was amazed and wondering how they keep track of all the separate wire clusters as they feed them into the slots.

 

[arther dailey]

its what I used to do thirty odd years back , on a mtr that size there would only be one of you working though ! to strip the stator about 1 1/2 hrs, wind coils on a machine about the same maybe two hours, rewind stator would be 8 hours at the most. used to do tiny stuff right up to 3.3kv . that certainly brings it back ! cant believe how much labour they throw at it, love the bodge on the bearing housing, bodged very neatly I may add.

 

[eddie49]

I was amazed and wondering how they keep track of all the separate wire clusters as they feed them into the slots.

Yes, me too. When they made up the coils, there were three "spool" guys sitting on the floor feeding wire to the "coil winder" guy. Reminded me of having to hold knitting wool spanned across my hands when my mother rolled it into a ball. Three guys = trifilar winding, but then I saw that each of them had a spool of wire on each hand, so the wound coils have six strands of wire in each? Then they stripped the enamel with an electric rotary tool, maybe this one:
https://www.ebay.co.uk/itm/DF-6-Ena...re-Stripper-Enameled-Copper-Wir-/362781914221
All the coil strands were then twisted together. These multiple strands in parallel are perhaps to handle the current...?

 

[Spark plug]

cant believe how much labour they throw at it

In India the Labour is the cheapest thing they used in the whole rewind, if they could have made the coils out of people they would have.