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Electric Motors Winding and Repair Electric Motors Winding and Repair Discussion


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Old 02-07-2012, 11:21 PM   #1 (permalink)
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Please add your favourite tools here, i use basically only the pliers in pic, groove in middle both sides so wires dont slip and polished edges as well as a couple of hotliner props, cellphone pic so pls excuse quality
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Old 02-08-2012, 07:06 AM   #2 (permalink)
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the shown kind of pliers works bad!

better to use such type (left "original" right hand side "made useful" ) for motorwinding:


the sides of these pliers come together in parallel.
the risk of hurting the insulation is much lower.
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Old 02-08-2012, 10:12 AM   #3 (permalink)
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look for:

Knipex Zangenschlüssel 8603 150mm
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Old 02-08-2012, 12:35 PM   #4 (permalink)
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Thanks a lot Ralph.
Here is a link to one of the US suppliers:
http://www.crawfordtool.com/knipex_plier_wrenches.html

We are talking about 40 bucks, but hey, we will have it for years to come. . .
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Old 02-08-2012, 02:15 PM   #5 (permalink)
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stolla

I made the same tool and after testing on a sample wire I too found it very easily slips and can take a nice chunk out of the copper insulation coating so I did just that added a groove.

Add just enough stability when press down.




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Please add your favourite tools here, i use basically only the pliers in pic, groove in middle both sides so wires dont slip and polished edges as well as a couple of hotliner props, cellphone pic so pls excuse quality
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Old 02-08-2012, 09:19 PM   #6 (permalink)
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Thnx for link Ralph!
The groove definately makes all the diference but must confess the one Ralph recommends is a better proposition, been looking for something similar since i started but no luck, guess i have to import one!
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Old 02-09-2012, 12:57 PM   #7 (permalink)
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I would like to ask all of you, what other kind of equipment you use.

E.g. a lot of guys do a 1000 Volt test. Can be done with special Insulation Tester/ Megger.
What kind of experience you do have with those.
Looked some handheld ones up on the net. They go from 40 bucks up to 1500 bucks.
Big difference. I don't know, if we have use for all those expensive built-in features.
What do we really need here?

On the same token, how do you guys hold your stator. With a vice or by hand?

I saw the vice method in the winding video and found it a good idea except the jaws didn't have any soft cover, aluminum, lead etc.
So, I prepared my small Hobby vice in a way by fabricating two pieces of Lexan, which are screwed to the jaws in order to protect the stator from getting damaged.
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Old 02-09-2012, 01:19 PM   #8 (permalink)
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I've seen other use the vice but not clamping on the stator. I think clamping the stator as you explained can distort it I guessing.

instead they used a wood dowel that fit tightly through the stator inner diameter and then clamp in a vice. Seem like a safer option.


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Originally Posted by ZuvieleTeile View Post
I would like to ask all of you, what other kind of equipment you use.

E.g. a lot of guys do a 1000 Volt test. Can be done with special Insulation Tester/ Megger.
What kind of experience you do have with those.
Looked some handheld ones up on the net. They go from 40 bucks up to 1500 bucks.
Big difference. I don't know, if we have use for all those expensive built-in features.
What do we really need here?

On the same token, how do you guys hold your stator. With a vice or by hand?

I saw the vice method in the winding video and found it a good idea except the jaws didn't have any soft cover, aluminum, lead etc.
So, I prepared my small Hobby vice in a way by fabricating two pieces of Lexan, which are screwed to the jaws in order to protect the stator from getting damaged.
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Old 02-09-2012, 01:19 PM   #9 (permalink)
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powercroco.de/wickelwerkzeug
I hold the stators only with my left hand.
every type from 13mm up to 400mm diameter.
there is absolutely no need to hold it harder!
I use also 2,5mm diameter wire in this way.

for 1000V test I use a voltcraft VC 1000.
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Old 02-09-2012, 01:22 PM   #10 (permalink)
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that link didn't work.

is this correct
http://www.powerditto.de/wickelwerkzeug.html

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www.powercroco.de/wickelwerkzeug.html

I hold the stators only with my left hand.
every from 13mm to 400mm diameter.
there is absolutely no need to hold it harder!
I use also 2,5mm diameter wire in this way.

for 1000V test I use a voltcraft VC 1000.
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Old 02-09-2012, 03:55 PM   #11 (permalink)
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Quote:
Originally Posted by powercroco View Post
powercroco.de/wickelwerkzeug
I hold the stators only with my left hand.
every type from 13mm up to 400mm diameter.
there is absolutely no need to hold it harder!
I use also 2,5mm diameter wire in this way.

for 1000V test I use a voltcraft VC 1000.


I also use only my hands, tried a vice once on my first wind but too restricted, i like to move the stator around when i wind
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Old 02-10-2012, 08:27 AM   #12 (permalink)
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Great that HF has a special winding subforum now
No need for a vise, I also use my hands and the Knippex pliers posted in post #2. That is the best investment you can do! You don't need to grind it, a couple of good steel files (and a vise for clamping the pliers) will do the trick quicker than you think. Doing that with a dremel will take much longer.
The Megger I use is a China version, selectable in 250V, 500V and 1000V. Works great!
http://www.ebay.nl/itm/VC60B-Digital...item3cc10f74a6
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Old 02-10-2012, 08:36 AM   #13 (permalink)
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Quote:
Originally Posted by _Dekker View Post
Great that HF has a special winding subforum now
No need for a vise, I also use my hands and the Knippex pliers posted in post #2. That is the best investment you can do! You don't need to grind it, a couple of good steel files (and a vise for clamping the pliers) will do the trick quicker than you think. Doing that with a dremel will take much longer.
The Megger I use is a China version, selectable in 250V, 500V and 1000V. Works great!
http://www.ebay.nl/itm/VC60B-Digital...item3cc10f74a6
In regards to the width of the Knipex, did you grind/file it smaller, or does it fit in the slot of our 40mm and up stators?
Funny thing, yesterday I ordered the same Megger. It is pretty cheap, so no harm done, if it is not sufficient or fails.
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Old 02-10-2012, 08:55 AM   #14 (permalink)
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Quote:
Originally Posted by ZuvieleTeile View Post
In regards to the width of the Knipex, did you grind/file it smaller, or does it fit in the slot of our 40mm and up stators?
Funny thing, yesterday I ordered the same Megger. It is pretty cheap, so no harm done, if it is not sufficient or fails.
This is mine:


I did modify the width a little, you have to find out for yourself if it will help you or not:
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Old 02-14-2012, 08:29 AM   #15 (permalink)
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Quote:
Originally Posted by ZuvieleTeile View Post
Thanks a lot Ralph.
Here is a link to one of the US suppliers:
http://www.crawfordtool.com/knipex_plier_wrenches.html

We are talking about 40 bucks, but hey, we will have it for years to come. . .
Thats cheap locally quote 80usd, gonna shop around and import a couple rather
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Old 02-14-2012, 04:13 PM   #16 (permalink)
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Knipex pliers in canada go for 125.00 CAD


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Thats cheap locally quote 80usd, gonna shop around and import a couple rather
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Old 02-16-2012, 10:35 AM   #17 (permalink)
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Well i just got one of these knippex beauties I wanted 2 but was the only one in stock so i'm reluctant to grind it as it's such a nice tool guess i'll have to order another!
Can you give me an indication as to the thickness of the tips so i dont grind down too much. Also doesnt the tips deform when so thin?, i know i have to bend my tools back into shape every now and then.
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Old 02-16-2012, 11:06 AM   #18 (permalink)
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hope, this photo will help.
I had no problem with deformation - and I just used it with 2,5mm wire on my HK 7050 prototype.

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Old 02-16-2012, 04:27 PM   #19 (permalink)
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When you grind it down and it is getting blue, do you have to harden it by cooling with water right away?
Something from far in the past is in my head, that it might get soft, if we don't do it right.
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Last edited by ZuvieleTeile; 02-16-2012 at 09:01 PM..
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Old 02-16-2012, 11:13 PM   #20 (permalink)
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Thanks for the pic Ralph, that 's perfect!
Zt I reckon if you work slow with the grinding so it doesn't get too hot should be ok, Dekker used hand files but I'm not gonna buy some for this job only, so maybe saw some of the chuncks then slowly grind with powerfile.
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