How To Optimize And Test The Performance of Motor Windings？

As the core component of the motor, the performance of the motor winding directly affects the operating efficiency, heat generation and life of the whole machine. For manufacturers and users, understanding how to optimize and test the performance of windings can not only improve the quality of the motor, but also effectively reduce energy consumption and maintenance costs.

1. Methods for optimizing the performance of motor windings

Optimize wire diameter and wire material selection

Choose appropriate enameled copper wire or aluminum wire according to the motor power and usage scenario. Too thin wire diameter will lead to increased resistance and severe heat generation; while too thick wire diameter will increase the volume of the winding, which is not conducive to heat dissipation and compact structural design. High-quality enameled wire can also improve insulation performance and reduce the risk of breakdown.

Reasonable design of winding structure

Use centralized or distributed winding structure and optimize the layout according to specific application scenarios. For example, centralized winding is more efficient in high-speed motors, while distributed winding is suitable for equipment that requires low noise and high stability.

Improve filling rate and heat dissipation capacity

Increasing the copper wire filling rate in the stator slot helps to reduce resistance loss. At the same time, the heat dissipation performance of the winding can be enhanced to avoid overheating and aging by combining varnish curing, stator punching lamination lamination process, winding ventilation design and other means.

Use automated winding equipment

Modern automatic winding machines have functions such as tension control, interlayer isolation, and automatic reversing, which can effectively improve the consistency of winding quality and reduce human errors.

2. Key points of performance testing of motor windings

DC resistance test

By measuring the DC resistance of the winding, evaluate the conductor resistance loss, judge the consistency of the winding and whether there is a local short circuit.

Inter-turn insulation test

Apply high voltage pulses at both ends of the winding to detect whether there is a breakdown or weak insulation point between the turns of the winding. The quality of inter-turn insulation is related to the withstand voltage level and long-term safe operation of the motor.

Dielectric strength test (withstand voltage test)

Applying high voltage between the winding and the core to detect whether it can withstand the rated insulation strength is an important test link before the product leaves the factory.

Temperature rise and thermal test

By loading and running, monitor the temperature rise curve of the winding under different working conditions, evaluate its heat dissipation and overload capacity, and verify whether the design is reasonable.

Vibration and noise test

Unbalanced winding distribution or assembly problems will cause unnecessary mechanical vibration and electromagnetic noise when the motor is running, so professional equipment is needed to perform spectrum and sound pressure tests.

Conclusion

The optimization and testing of motor windings is a systematic project, covering material selection, structural design, process control and detection methods. Only by striving for excellence in every link can we create efficient, reliable and durable motor products. In the context of increasing attention to energy saving and intelligent manufacturing today, the importance of winding optimization technology has become increasingly prominent.