Hybrid Car – More Fun with Less Gas

A question about coil winding - Page 6

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Posted by amdx on December 8, 2009, 12:07 am

Your comments about the winding was well atriculated,
thank you. I'm in the process of making a winding jig. And
probably using #30 wire.

Just be sure to make at least one side of your jig movable
(removable) or you will never get it off the jig.
Depending on your jig, it's nice to lay several strips of tape, adhesive
side up on the jig, so when your finished winding you can wrap the
wires to stablize them before removing from jig. (string also works).

Posted by Michael B on December 8, 2009, 12:49 am

A good reminder, likely borne of experience. But I'm
figuring on varnishing (and maybe fishpapering) from
layer to layer. That should stabilize windings nicely.
These things are gonna be moving.

Posted by amdx on December 8, 2009, 3:45 am

.A good reminder, likely borne of experience. But I'm

 I haven't a clue about your form, but I don't know how
you put it in a motor after it's varnished.

Posted by Josepi on December 15, 2009, 4:08 am

You don't put it in after it is varnished. You varnish the windings in the
core to hold things tight from vibration and conduct the heat away from the

Posted by m II on December 17, 2009, 5:03 am

Josepi wrote:

When you are winding coils, you most certainly can brush or spray the
Glyptal on each layer before starting the next one. Take it slow and you
won't even get your fingers covered like I did.

Secondarily, I am not aware of ANY varnish type coatings that help to
carry heat away from the wire. Every coating I am aware of acts as an
insulation to some degree. Some web sites talk of 'special resins' with
certain fillers which help in heat conductivity. I don't know anything
about them.

Centrifugal force may be a bigger danger than vibration. Now, having
said that, there MAY be a particular RPM where a resonance is set up in
the coils. Thee should be a way of testing for that before any sort of
mass production takes place.


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