Lead wire rotor winding is a process of winding wires around the rotor of a motor to create the rotating part of the motor. Lead wire winding forms the windings of the rotor, which creates a magnetic field through the flow of electricity through the wires, which results in the operation of the motor.

The design of the rotor is first needed to determine its shape, size and winding structure. The rotor usually consists of a core and windings. The core provides the structural support and magnetic circuit of the rotor, while the windings are responsible for carrying the current and generating the magnetic field. The appropriate wire material is selected based on the needs and design requirements of the motor. Common conductor materials include copper and aluminum, which have good electrical conductivity and heat resistance. The specification and cross-sectional area of the wire should be determined according to the current load and design requirements.


Wire rotor winding can be performed manually or with automated equipment. First, the starting point of winding is determined on the rotor and the winding is carried out according to the predetermined winding method. When winding, the wire needs to be tightly and evenly distributed on the rotor surface to ensure good current path and magnetic field generation.
The structure of the wire winding can be a single-layer winding or a multi-layer winding. Single-layer winding involves winding the wires on only one level of the rotor, while multi-layer winding involves winding the wires on multiple levels. Multi-layer windings provide a larger number of turns and a stronger magnetic field.

Once the winding is complete, the wire needs to be secured and cured to ensure the stability and reliability of the winding. The windings can be coated with an insulating varnish or curing agent, which is cured to enhance their mechanical strength and insulating properties. Connections are required between the wound conductors to form a continuous current path. The connections can be made by soldering, crimping or winding specific connecting wires. These connections require good electrical contact and mechanical strength.

Quality control is required during the winding process, including checking the number of turns wound, insulation quality, connection quality and cosmetic defects. Resistance and insulation tests are also required to ensure that the windings meet specifications and requirements. Leaded rotor winding is an important step in the motor manufacturing process and has a significant impact on the performance and efficiency of the motor. Proper winding and good quality control can improve the performance, reliability and life of the motor.