Motor Winding Parts List & Diagram
Applicability: This document continues the 36-slot / 4-pole / 3-phase example from earlier (30
turns per coil, 6 coils/phase → 180 turns/phase, MLT = 0.25 m).
1) Quick summary (design parameters)
Stator slots: 36
Poles: 4 (pole pitch = 9 slots)
Coils: 18 coils (two-layer winding, each coil spans 9 slots)
Coils per phase: 6
Turns per coil: 30
Turns per phase: 180
Mean length per turn (MLT): 0.25 m (adjust to your stator geometry)
Wire: 2.5 mm² enamelled copper (recommended) or 2 × 1.25 mm² parallel
2) Complete parts list (what to buy / prepare)
Electrical materials
Enamelled copper magnet wire — 2.5 mm², Class F or H enamel — 140 m
(recommended buy: 150 m).
Alternative: 2 × 1.25 mm² enamelled (same total copper area) — buy 2 × 150 m spools if
using parallels.
Flexible hook-up wire (for terminal leads and internal jumpers) — 1.0–1.5 mm², 5–10
m, high temperature.
Slot liners (mica or Nomex)** — enough to line 36 slots (cut strips to length).**
End-winding insulating sleeves (fiberglass or nomex tubes) — for coil heads and
crossover points.
Varnish (polyester or epoxy for dipping/brush; use manufacturer-recommended class) —
1–2 liters.
High-temp heat-shrink tubing or insulating sleeving — assorted sizes.
High-temperature binding cord / string for securing end-windings.
Mechanical & hardware
Terminal box and three-phase terminal studs (or lug kit) — 3 line terminals + neutral if
Y connection used.
Crimp sleeves / solder sleeves (high-temp) for splices — pack of 50.
High-temperature solder & flux (if soldering joints) — rosin flux recommended.
Epoxy or potting compound (optional) for terminal box sealing.
Cable glands for external cable entry (quantity 3).
Tools & consumables
Coil winding jig or former (to keep turns neat) or manual winding setup.
Tensioning device or hand tensioner for wire.
Wire strippers for enamel (thermal or chemical stripper) and sandpaper for enamel
removal.
Crimping tool, soldering iron / torch (as needed for splices).
Insulation tester (megger), LCR meter (for inductance/resistance verification), and DC
multimeter.
Varnish brush and vacuum oven or setup for varnish cure (if available).
3) Quantities & lengths (detailed)
Per coil length (30 turns): 30 × 0.25 = 7.5 m
Per phase length (180 turns): 180 × 0.25 = 45.0 m
Total length (3 phases): 135.0 m
Buy quantity recommendation: 150 m (adds ~11% spare)
4) Slot-by-slot diagram (36 slots)
Below is a circular slot map rendered in text. Slots are shown clockwise. Each slot entry shows:
Slot #: Coil # (Phase, Side, Polarity) where Side indicates layer (Top or Bottom) and Polarity is
+ for coil start, - for coil end.
[31] [32]
[30] [29] [33] [34]
[29] ... etc (visualized in a circle) ...
Note: A simple text circle is limited. For clarity use the slot table below (explicit mapping) or
ask for a PNG of the circular map.
Slot table (slot → coil, phase, side, polarity)
1. Slot 1: Coil 1, Phase A, Start (+)
2. Slot 2: Coil15, Phase C, End (−)
3. Slot 3: Coil 2, Phase B, Start (+)
4. Slot 4: Coil16, Phase A, End (−)
5. Slot 5: Coil 3, Phase C, Start (+)
6. Slot 6: Coil17, Phase B, End (−)
7. Slot 7: Coil 4, Phase A, Start (+)
8. Slot 8: Coil18, Phase C, End (−)
9. Slot 9: Coil 5, Phase B, Start (+)
10. Slot 10: Coil 1, Phase A, End (−)
11. Slot 11: Coil 6, Phase C, Start (+)
12. Slot 12: Coil 2, Phase B, End (−)
13. Slot 13: Coil 7, Phase A, Start (+)
14. Slot 14: Coil 3, Phase C, End (−)
15. Slot 15: Coil 8, Phase B, Start (+)
16. Slot 16: Coil 4, Phase A, End (−)
17. Slot 17: Coil 9, Phase C, Start (+)
18. Slot 18: Coil 5, Phase B, End (−)
19. Slot 19: Coil10, Phase A, Start (+)
20. Slot 20: Coil 6, Phase C, End (−)
21. Slot 21: Coil11, Phase B, Start (+)
22. Slot 22: Coil 7, Phase A, End (−)
23. Slot 23: Coil12, Phase C, Start (+)
24. Slot 24: Coil 8, Phase B, End (−)
25. Slot 25: Coil13, Phase A, Start (+)
26. Slot 26: Coil 9, Phase C, End (−)
27. Slot 27: Coil14, Phase B, Start (+)
28. Slot 28: Coil10, Phase A, End (−)
29. Slot 29: Coil15, Phase C, Start (+)
30. Slot 30: Coil11, Phase B, End (−)
31. Slot 31: Coil16, Phase A, Start (+)
32. Slot 32: Coil12, Phase C, End (−)
33. Slot 33: Coil17, Phase B, Start (+)
34. Slot 34: Coil13, Phase A, End (−)
35. Slot 35: Coil18, Phase C, Start (+)
36. Slot 36: Coil14, Phase B, End (−)
5) Winding connection diagrams (series chains)
Phase A (series chain)
Sequence (example wiring order minimizing crossovers):
A_start = Coil1(start +) → Coil1(end −) splice → Coil4(start +) → Coil4(end −) splice →
Coil7(start +) → Coil7(end −) splice → Coil10(start +) → Coil10(end −) splice → Coil13(start
+) → Coil13(end −) splice → Coil16(start +) → Coil16(end −) = A_finish
A_start becomes terminal L1 (or connect to delta/Y as needed).
Phase B (series chain)
B_start = Coil2(start +) → Coil2(end −) → Coil5(start +) → Coil5(end −) → Coil8(start +) →
Coil8(end −) → Coil11(start +) → Coil11(end −) → Coil14(start +) → Coil14(end −) →
Coil17(start +) → Coil17(end −) = B_finish
Phase C (series chain)
C_start = Coil3(start +) → Coil3(end −) → Coil6(start +) → Coil6(end −) → Coil9(start +) →
Coil9(end −) → Coil12(start +) → Coil12(end −) → Coil15(start +) → Coil15(end −) →
Coil18(start +) → Coil18(end −) = C_finish
6) Terminal wiring: Star (Y) and Delta (Δ)
Star (Y): Connect A_finish, B_finish, C_finish together to form neutral (N). External
supply lines go to A_start, B_start, C_start.
Delta (Δ): Make three jumpers: A_finish → B_start, B_finish → C_start, C_finish →
A_start. The three junctions are the line terminals.
7) Parts diagram (textual wiring schematic)
[A_start] --- Coil1 ---+--- Coil4 ---+--- Coil7 ---+--- Coil10 ---+---
Coil13 ---+--- Coil16 --- [A_finish]
| | | |
|
[B_start] --- Coil2 ---+--- Coil5 ---+--- Coil8 ---+--- Coil11 ---+---
Coil14 ---+--- Coil17 --- [B_finish]
[C_start] --- Coil3 ---+--- Coil6 ---+--- Coil9 ---+--- Coil12 ---+---
Coil15 ---+--- Coil18 --- [C_finish]
Each --- represents the coil (30 turns) and + are the splices between coil ends and next coil starts
in the series chain.
8) Tests, QC & expected measurements
DC resistance per phase (calculated for 2.5 mm²): ~0.31 Ω. Measured cold resistance
should be within ±5–10% of this depending on exact MLT and finish.
Insulation resistance (megger): > 1 MΩ (for small motors) — goal > 100 MΩ after
varnish depending on environment.
No-load test: measure phase currents and magnetizing current, check phase balance.
Locked rotor test: measure starting current and torque if instrumented.
9) Optional: slot-fill & packing check
Calculate slot copper area (measure or get from stator drawing).
Conductor total area per slot = number of conductor sides in slot × conductor area (+
enamel).
Target slot fill for medium motors: 45–65% depending on insulation stack-up.
If you provide your slot copper area (mm²), I’ll calculate exact slot-fill % for the chosen
conductor.
10) Next deliverables I can produce now (pick one)
A PNG or SVG circular slot diagram with coil sides color-coded (I can generate and
deliver).
A CSV parts & slot table ready for printing to use on the workshop floor.
A PDF with the full diagram and shopping list (ready to download).
Tell me which output you want and I’ll produce it immediately.
