Manufacturing Techniques for Electric Motor Coils With Round Copper Wires

To design and manufacture electric machines that are competitive in terms of cost, performance, and efficiency, various parameters must be considered. Winding type selection and manufacturing are among these aspects. The winding needs to be designed optimally according to the electric machine type and application. Choosing the suitable magnet wire is one of the essential steps in winding design and manufacturing. For this purpose, several parameters need to be considered, including the diameter, thermal class, conductor type, and insulation material of the magnet wire. Also, the type and material of the bobbin should be selected properly. The tension applied to the wire during the winding process is an important parameter to achieve perfect layering and a high fill factor. Automatic winding techniques can be chosen according to the winding process requirements and the manufacturing volume. Different steps in the manufacturing process of electric machine coils are investigated in this paper, including the factors that should be taken into account to have a high-quality product. For design-for-manufacturing considerations, the approaches for selecting the proper magnet wire, insulation, bobbin, and layering technique are presented. Finally, different winding techniques are introduced, and their specifications and capabilities are discussed and compared.