Continuity phase winding is a quick method of rewinding in certain applications. This method eliminates jumper connections, saves time on coil insertion, saves materials, and can save time when winding coils and setting the heads.

Continuity phase winding can only be used for series wye or series delta connections. For a parallel connection, data would have to be changed to use the continuity phase method. This would require a departure from specifications. Therefore, it is recommended that this method be used only for a series-type connection.

Selecting phase head

Measure the distance from the bottom of the slot that one coil side lays in to the top of the slot the other coil side lays in.

The phase head nearest this measurement will be the one to use. The width of the stator core, plus end room, will be the approximate dimension for the length of the coil to be set.

Selecting length of sleeving

Sleeving should be placed over the wire before beginning to wind the coils.

One piece of sleeving must cover the crossover.

A length of sleeving for each crossover must be positioned on the wire before beginning winding of each phase.

Use a length of sleeving that fits the curvature of the winding head.

Coil winding

Open and lock the winding head.

Ensure that the proper phase head has been selected.

Set in the length of coil.

Ensure that the guide bar is in place.

Position the required size wire on the dereeler.

Lead the wire from the dereeler through the tensioning device to the winding head. Set the tensioning device lightly on the wire.

Check for the proper speed setting and direction of rotation of the winding head.

Set the counter to zero. On automatic machines, set in the number of turns per coil.

Wind a sample coil.

Unlock the winding head and remove the sample coil.

Lay the sample coil in the stator in which the coils are to be installed.

Check the fit of end room and span.

Make any necessary adjustments on the winding head to ensure proper size coils.

Open and lock the winding head and install jumper sleeving. Set the machine to wind a phase. A phase consists of several coils wound in series.

Use a system to note crossover with the proper turns in each coil.

The crossover is the point of change over from one coil to another.

Ensure that the sleeving is slid over onto the crossover.

The crossover must be made at the same point on all coils. The first coil entered the slots on the phase head.

After the phase is wound, tie the sides of each coil with cotton twine. Use a type of knot that will pull out easily.

Cut the wire and remove the phase from the winding head.

The coils are placed on the left arm, with the leads and crossovers down.

Turn the first group of coils 180 degrees clockwise and place them on the coil rack.

As used below, straight means in the same manner as it was wound.

Place the end group of coils on the coil rack straight.

Turn the third group of coils 180 degrees clockwise and place them on the coil rack.

Place the fourth group of coils on the coil rack straight.

Check to ensure that the coils have been turned properly. This is done by noticing the crossovers.

There should be a crossover on the left side between the first and second groups.

There should be a crossover on the right side between the second and third groups.

There should be a crossover on the left side between the third and fourth groups.

All three phases of coils are placed on the rack in the same manner.

Tape the end turns of each coil with one layer of glass thermosetting tape. Do NOT tape the crossovers or leads.

The phases are to remain on the coil rack until they are to be inserted into the stator.

Click on image to enlarge.

Closeup of Winding Head