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Winding Data Calculation
TERMS
Although the data submitted by us are obtained from reliable sources, we do not give any guarantee and do not accept responsibility for any personal, professional, or financial risk or any resulting injury, accident, or loss as a result of using our information. Any information obtained by us ( diagrams, calculations, winding details) should only be implemented by professional and fully qualified electrical engineers using their own professional judgment and due regard to health and safety issues. Using data obtained by us is solely at your own risk.
The calculation will be performed for the air-cooled, three-phase motors for continuous duty cycle S1, standard efficiency, 50 or 60 Hz, SF= 1.00, lap or concentric, single or double-layer, for the maximum power from the given iron core.
Please, provide as much info as possible, in order that we'll be able to make a reliable calculation.
NOTICE:
This service is not free of charge.
Submit the needed info and explain in detail what you need and we'll get back to you with our offer/ price in advance. Prices are starting from 20 USD upward per calculation or diagram and depend on motor power and complexity of windings.
Payment is via PayPal using any credit card with no additional transfer fees to you. Note, you don't have to have your own PayPal account.
IMPORTANT NOTICE: MONEY REFUND IS NOT POSSIBLE.
Why?
First of all, the accuracy of calculation or diagram depends on the input data provided by yourself.
The success of the repair depends entirely on your work, expertise, material quality, testing, etc.
Any information obtained by us ( diagrams, calculations, winding details) are just propositions and should be considered and implemented only by professional and fully qualified electrical engineers using their own professional judgment and due regard to health and safety issues.
Pay attention especially in case of a winding redesign, poles-change for example. In some rare cases, it happens that the new number of poles is not suitable for a particular number of rotor bars, which is impossible to determine in advance.
Using data obtained by us is solely at your own risk.
The onus in on you.
Once you have received our information you paid for (data calculation report or diagram), it is considered you've seen and consumed our service and there is no way to quit and ask for a refund.
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The calculation will be performed for the air-cooled (TEFC, ODP), three-phase motors for continuous duty cycle S1, standard efficiency, 50 or 60 Hz, SF =1.00, lap or concentric, single or double-layer, random wounds winding for the maximum power from the given iron core.
The calculation will be performed for the air-cooled, three-phase motors for continuous duty cycle S1, standard efficiency, 50 or 60 Hz, SF 1.00, lap or concentric, single or double-layer, for the maximum power from the given iron core.
Please, carefully review the information needed, and be aware that more details gives more accurate results.
Attaching a few pictures of motor stator, slots, rotor, in order to detect and avoid erroneous measurements, is always a good practice.
What data you need?
( remember: bold data are mandatory)
- line to line voltage (V) ,
- frequency (Hz) ,
- star or delta connection ,
- number of poles or rpm ,
- all other nameplate data if available,
- stator slots ,
- core internal diameter (mm) ,
- core external diameter (mm) ,
- core length,
- number and width of air vents if exist,
- back-iron (mm) ,
- tooth-width (mm) --- if tooth is trapezoidal, enter the both
dimensions a (mm) and b (mm)
In case of single-phase windings with different number of t/c,
the iron core could be in more complex form and, obviously,
an additional dimensions should be recorded ( see the picture below).
- rotor bars ,
- skewed rotor bars or stator slots (yes or no) .
Each additional note is useful:
- previous 'no-load' current, if is known,
- what is the reason for calculation?
- irregularities in previous work,
- load and environmental conditions,
- motor application (pump, fan etc...),
- duty cycle ( S1 - continuous work or other),
- photos of nameplate, stator, rotor, slot , and damaged windings.
- all previous winding data ( if available),
Please,submit data to online form .
Write down the number and width of air vents if exist
If the iron core is in some of the following forms ( see the pictures below), an additional designated measures are needed. Also, the photo of core could be very useful.
Back Iron with Bolt Holes
Back Iron with Notches
Back Iron with Flats
Back Iron with Notches and Flats
Round Core with diff. Slots
The slot dimensions are not mandatory if you consider that previous slot - filling was "normal".
In that case write down the previous number of turns per slot an wire size.
Otherwise, the slot shape should be determined and slot dimensions measured according to picture .
If your slot shape is different from these shown, please, attach your own drawing or make a slot&teeth imprint on paper using a marker, then scan and submit it to us ( see the pictures below).
You need to measure the slot. How?
- Use the marker in order to make a imprint of slot on the paper. Then you have to recognize the shape and do the necessary measurements or make a scan and submit it to us ( see the pictures below).
- Slot imprint can be obtained using clay or a similar material, also.
- If you're lazy and do not want to measure it, then do a test coil of any similar wires until you get satisfactory slot filling. Then let us know the number and size of wires in the slot
Another way to measure the slot:
- Cut a piece of metal sheet ( thickness of 1 mm) in the trapezoidal shape. The length is according to your needs, approximately 200 mm and a width of 3 mm on one side and 20 mm on the other side. This simple tool will improve your measurements.
- Buy ready to use tool
One more way:
- Carefully measure the teeth - width and the overall height of the slot, as is shown in the photo.
- Take a high quality shot of slot area (camera must be perpendicular to the surface of the core) and send it to us.
With these data we will calculate the area of the slot.
It must be emphasized if the motor is
encapsulated (see the photo below).
Preferably describe the motor cooling method or attach pictures of the motor, rotor, fan, etc. Otherwise, we will assume the motor is IC 411 (TEFC).
Click on the image to the left for more.
AC Windings
Or click on the choosen link below:
Please, submit all the information you have.
After Calculation:
Always try the slot fill with the test coil.
Choose a thicker wire if there is enough space, but don't change the turns/coil.