Cousins DR1

Thanks, its Nomex 410. I bought several thickness (20 & 10 mil thick ) a few years ago when I was hoping to rewind the stalled DR-2. This is the 20 mil thick going in first.

So I have been very busy trying to learn how to rewind a stator. Reading more, trying the coil winder, trying to make coils fit in the slots. It's been a lot of work but I am getting it I think.
After measuring the new coil form and the stator I thought I needed to start to make the run wining coil on the next to the smallest step and then skip one step and use the largest two. So I grabed some extra wire rather than use the hermetic wire and stated to practice making coils.Well that was way too big.



Tried winding by hand but it was very loose back in the middle of the slot. 


I also make a sample coil set starting on the next to the smallest step on the form and then the next two steps. That didn't seem to fit too bad.




 I also tried several things to cover the edges of the slots to keep the new wire from rubbing. Didn't want to use tape and leave adhesive.


Tried some thinner pieces I cut out of Nomex and clips made from braze rod. They worked the best but couldn't keep them in place.


So after I was pretty sure that coils made on the 2nd, 3rd and 4th steps of the form was going to work I broke out the good wire and made a full coil set for one pole out of four in the run winding.



They came out so nice looking.

I am not sure how the pros feed all this in such small slots when the coils is preformed and has so many turns. I tried several ways to hold the end and spread the rest out but 35- 50 turns can get intermixed and hard to work them all in right. 

Here is the first part of the coil in the slots. I wasn't using any dowels to push the windings into the slots and they are too loose. 

I did manage to get all three sections on the winding in the slots but the smallest section was too long. The other end came out ok but this end overlapping is pushing the other wire out too far. There will not be enough room for the start winding to go in right.


Next I tried winding bay hand again but using smooth plastic rods to hold things in place better. Its time consuming but came out pretty good so far. Hardest part is not loosing count of the turns you have done lol.





I even shot you all a few videos .

youtu.be/C98cS2baegk

youtu.be/KnVSJoi0bz4

youtu.be/wVgSrQaHt9Y

I'm not NEARLY patient enough to do that. Kudos!

Hi Gill. That's certainly a learning experience I'm sure. Remembering my little 4-coil motor rewind, I certainly can understand how much time this will take.

As for feeding the coils in through the slots, I've seen some winders leave the slot liners long, so that they come out into the rotor area. The two ends are then spread apart, to make a "chute" which will compress and guide the coils through the slot. Another technique I have seen in videos was to wrap a "horseshoe" of Nomex or some other similar material around the coil, with the open ends of the horseshoe inside the slot. Then you can use this like the "chute" above to compress and guide the winding through the gap in the stator core. Again; I haven't used these techniques but saw them while researching to rewind my Vornado fan motor.

Thanks for keeping us posted and really enjoying watching your progress!

Sincerely,
David

Here is one of the few original slot liners that is in tact. I don't know if the extra paper was used to protect the windings going in or not. Not sure they were long enough at only about 3/32" wide.



I made one like the original out of the thinner Nomex. If I bend the edges first and if I bring them up through the slot its so pinched shut that its too short to help guide the wire in.
I also stuck an piece of the Nomex in thinking about this horse shoe idea. You can't see it all in the pic but it was a loose fit in the stator.


I next thought that two horse shoes at once might work. I cut a thinner piece of Nomex the long way ( just over 12") x 2 1/4" wide like the slot liners  and thought it to long for two to fit. I was going to cut it shorter but realized it fills the I.D. of the stator and helps keeps its self in place the way it is. I was able to put a tangled mess off the work bench in pretty good and the other 1/2 of the coil wasn't rubbing on metal either, just Nomex.  


I also made some more trial coils after thinking about the overly long inter loops. I realized If I can turn the larger two sections first, secure them, reset the coil form smaller by 1/2" and then turn the smallest coil I may be able too use the form I have.  Sorry Ray, the theraputic hand winding videos may be over with lol

I’m just glad you’re making progress!

Still making progress, have the run windings almost done. 



Here is a rather long couple videos of the last pole going into the stator.

youtu.be/XO6yhPSJyIc

youtu.be/4-KW7JiD-xc