Lead wire rotor winding is the process of winding wires around the rotor of a motor to form the rotating part of the motor. The windings of the lead wires form the rotor winding, which is used to pass current through the wires and create a magnetic field to operate the motor.

The design of the rotor begins with determining its shape, size and winding configuration. The rotor generally consists of an iron core and windings. The core provides the structural support and magnetic path of the rotor, while the windings are responsible for carrying the current and generating the magnetic field. Select the appropriate wire according to the needs and design requirements of the motor. Common conductive materials include copper and aluminum, which have good electrical conductivity and heat resistance. The conductor size and cross section should be determined according to the current load and design requirements.

Wire rotor winding can be done manually or using automated equipment. First, the starting point for winding is determined on the rotor and the wire is wound according to a predetermined method. When winding, the wire must be tightly and evenly distributed over the rotor surface to ensure good current flow and to generate a magnetic field.



The winding may be constructed as a single-layer winding or as a multi-layer winding. Single-layer winding involves winding the wire around a single layer of the rotor, while multi-layer winding involves winding the wire around multiple layers. Multi-layer windings provide more turns and a stronger magnetic field.

Once the winding is complete, the wire must be secured and cured to ensure stability and reliability of the winding. The windings may be coated with an insulating bonding varnish or curing agent that enhances their mechanical strength and insulation properties after curing. Connections between the wound conductors are required to form DC paths. Connections can be made by soldering, crimping or winding specific connecting wires. These connections require good electrical contact and good 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 necessary 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 motor performance and efficiency. Proper winding and good quality control can improve motor performance, reliability and life.