🔧 Simple Explanation: How to Rewind an Electric Motor
1. Open the motor
- Remove the end covers.
- Bring out the stator (the part with the windings inside slots).
2. Study the old winding
Before you remove anything:
- Check how many coils are in the motor.
- Count how many turns are in each coil.
- Check the wire size (thickness).
- Note how the coils are joined (Star or Delta).
This is your guide. Always copy what the manufacturer designed.
3. Remove the burnt windings
- Cut out all old coils.
- Clean the slots.
- Put new insulation paper inside each slot to protect the new wire.
4. Wind new coils
- Use the same wire size and same number of turns you counted.
- Wind coils neatly and tightly.
- Make all coils for the three phases (U, V, W).
5. Insert coils into the stator
- Put the coils back into the slots exactly like the old ones.
- Follow the correct slot pattern and coil pitch.
- Use slot wedges to lock the coils so they do not move.
6. Connect the phases
Three-phase motors are connected in:
Star (Y)
- All coil ends are joined together.
Delta (Δ)
- The end of one coil connects to the beginning of the next coil.
Connect it the same way the old winding was connected.
7. Tie, insulate, and varnish
- Tie the coil groups with string so they stay firm.
- Apply insulation papers around the end windings.
- Dip the stator in insulating varnish and bake/dry it.
This makes the winding strong and safe.
8. Test the motor
Before closing the motor:
- Check continuity (each phase connected).
- Check insulation resistance (no short).
After assembling:
- Test run the motor:
It should run smooth, quiet, and cool.
🌟 Summary in one sentence
Rewinding a motor simply means removing the old burnt coils, preparing the stator, making new coils with the same number of turns and wire size, inserting them correctly, connecting the phases properly, insulating and varnishing, then testing the motor.