Todays deals on Winding Wire?

All New TES-1340 Digital Anemometer Air Wind Flow Meter,Hot-Wire Anemometer $270.00

New TES-1340 Digital Anemometer Air Wind Flow Meter,Hot-Wire Anemometer $268.00

New TES-1340 Digital Anemometer Air Wind Flow Meter Tester,Hot-Wire Anemometer $249.00

WIRE AND CABLE REELING – WINDING – MACHINE $145.00

441 Ft Wind Generator Magnet Wire – 11 Gauge 11 pounds $145.00

700 Ft Wind Generator Magnet Wire 13 Gauge, 11 pounds $145.00

505 Feet / 11 Lbs Magnet Wire 12 Gauge AWG HTAIH #12 Wind Generator 200 Degree C $145.00

23 Gauge ESSEX Wind Generator Magnet Wire 6894 Ft 11 Lb Copper Wire HTAIH $137.53

Essex Magnet Wire 21 Gauge for Wind Generator Copper Wire About 4354 Ft or 11 Lb $137.53

22 Gauge ESSEX Wind Generator Magnet Wire 5517 Ft 11 Lb $137.53

20 Gauge ESSEX Wind Generator Magnet Wire 3460 Ft 11 Lb $135.53

16 Gauge ESSEX Wind Generator Magnet Wire 1382 Ft 11 Lb Copper High Temperature $133.53

14 Gauge ESSEX Wind Generator Magnet Wire 11 LB Copper High Temperature HTAIH $133.53

15 Gauge ESSEX Wind Generator Magnet Wire 1096 Ft 11 Lb Copper High Temperature $133.53

18 Gauge ESSEX Wind Generator Magnet Wire 2189 Ft 11 Lb Copper High Temperature $133.53

19 Gauge ESSEX Wind Generator Magnet Wire 2755 Ft 11 Lb $126.53

12 AWG Gauge Enameled Copper Magnet Wire 10lb 500ft 200C Magnetic Coil Winding $124.57

25 AWG Gauge Enameled Copper Magnet Wire 7.5lb 7462ft 200C Magnetic Coil Winding $116.85

12 AWG Gauge Enameled Copper Magnet Wire 10lb 155C 500ft Magnetic Coil Winding $116.10

26 AWG Gauge Enameled Copper Magnet Wire 200C 7.5lb 9435ft Magnetic Coil Winding $113.49

24 AWG Gauge Enameled Copper Magnet Wire 7.5lb 5925ft 200C Magnetic Coil Winding $111.97

23 AWG Gauge Enameled Copper Magnet Wire 7.5lb 4695ft 200C Magnetic Coil Winding $110.07

26 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 9435ft Magnetic Coil Winding $108.55

24 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 5925ft Magnetic Coil Winding $108.52

Coil Wire Winding Mold Single Phase & Three Phase Coil Winding Head Holder $85.00

21 AWG Gauge Enameled Copper Magnet Wire 200C 7.5lb 2962ft Magnetic Coil Winding $106.66

16 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 937ft Magnetic Coil Winding $106.64

21 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 2962ft Magnetic Coil Winding $106.43

23 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 7042ft Magnetic Coil Winding $106.40

20 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 2355ft Magnetic Coil Winding $106.32

22 AWG Gauge Enameled Copper Magnet Wire 7.5lb 3757ft 200C Magnetic Coil Winding $105.51

22 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 3757ft Magnetic Coil Winding $104.09

11 AWG Gauge Enameled Copper Magnet Wire 10lb 397ft 200C Magnetic Coil Winding $102.08

10 AWG Gauge Enameled Copper Magnet Wire 10lb 315ft 200C Magnetic Coil Winding $102.07

15 AWG Gauge Enameled Copper Magnet Wire 7.5lb 750ft 200C Magnetic Coil Winding $101.78

20 AWG Gauge Enameled Copper Magnet Wire 7.5lb 2355ft 200C Magnetic Coil Winding $99.51

11 AWG Gauge Enameled Copper Magnet Wire 10lb 155C 397ft Magnetic Coil Winding $98.94

10 AWG Gauge Enameled Copper Magnet Wire 10lb 155C 315ft Magnetic Coil Winding $98.79

15 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 750ft Magnetic Coil Winding $98.78

12 AWG Gauge Enameled Copper Magnet Wire 7.5lb 375ft 200C Magnetic Coil Winding $98.64

16 AWG Gauge Enameled Copper Magnet Wire 7.5lb 937ft 200C Magnetic Coil Winding $98.48

19 AWG Gauge Enameled Copper Magnet Wire 7.5lb 1875ft 200C Magnetic Coil Winding $97.77

18 AWG Gauge Enameled Copper Magnet Wire 200C 7.5lb 1492ft Magnetic Coil Winding $96.62

13 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 472ft Magnetic Coil Winding $96.13

TECO WESTINHOUSE 61211HC MAGNET WIRE, MOTOR ARMATURE WINDING WIND WIRE, SIZE 040 $95.00

25 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 7462ft Magnetic Coil Winding $94.70

12 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 375ft Magnetic Coil Winding $94.23

ARDEE LIGHTING GENERAL PURPOSE TRANSFORMER 1 PHASE WINDING WIRE 80 C 120 x 240V $79.00

14 AWG Gauge Enameled Copper Magnet Wire 7.5lb 592ft 200C Magnetic Coil Winding $93.07

17 AWG Gauge Enameled Copper Magnet Wire 200C 7.5lb 1185ft Magnetic Coil Winding $92.81

13 AWG Gauge Enameled Copper Magnet Wire 7.5lb 472ft 200C Magnetic Coil Winding $89.38

30 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 15660ft Magnetic Coil Winding $88.64

28 AWG Gauge Enameled Copper Magnet Wire 5lb 9940ft 200C Magnetic Coil Winding $87.78

coils/wire winder 5100 counting double speed manually drive winding machine USG $51.00

25 AWG Gauge Enameled Copper Magnet Wire 5lb 4975ft 200C Magnetic Coil Winding $85.68

26 AWG Gauge Enameled Copper Magnet Wire 200C 5lb 6290ft Magnetic Coil Winding $82.98

24 AWG Gauge Enameled Copper Magnet Wire 200C 5lb 3952ft Magnetic Coil Winding $82.30

23 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 3134ft Magnetic Coil Winding $81.26

23 AWG Gauge Enameled Copper Magnet Wire 200C 5lb 3134ft Magnetic Coil Winding $80.97

11 AWG Gauge Enameled Copper Magnet Wire 7.5lb 275ft 200C Magnetic Coil Winding $80.66

10 AWG Gauge Enameled Copper Magnet Wire 7.5lb 236ft 200C Magnetic Coil Winding $80.64

11 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 275ft Magnetic Coil Winding $80.27

10 AWG Gauge Enameled Copper Magnet Wire 7.5lb 155C 236ft Magnetic Coil Winding $80.15

900′ Spool of 20 AWG Magnet Wire Turning / Winding $79.95

1500′ Spool of 22 AWG Magnet Wire Turning / Winding $79.95

22 AWG Gauge Enameled Copper Magnet Wire 200C 5lb 2507ft Magnetic Coil Winding $79.65

22 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 2507ft Magnetic Coil Winding $79.53

26 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 6290ft Magnetic Coil Winding $79.10

21 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 1975ft Magnetic Coil Winding $78.38

20 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 1573ft Magnetic Coil Winding $78.33

21 AWG Gauge Enameled Copper Magnet Wire 200C 5lb 1979ft Magnetic Coil Winding $78.27

20 AWG Gauge Enameled Copper Magnet Wire 200C 5lb 1573ft Magnetic Coil Winding $78.07

19 AWG Gauge Enameled Copper Magnet Wire 200C 5lb 1252ft Magnetic Coil Winding $77.15

16 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 625ft Magnetic Coil Winding $76.75

14 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 395ft Magnetic Coil Winding $76.60

17 AWG Gauge Enameled Copper Magnet Wire 200C 5lb 789ft Magnetic Coil Winding $76.29

15 AWG Gauge Enameled Copper Magnet Wire 5lb 500ft 200C Magnetic Coil Winding $75.67

600′ Spool of 18 AWG Magnet Wire Turning / Winding $74.95

24 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 3952ft Magnetic Coil Winding $74.81

12 AWG Gauge Enameled Copper Magnet Wire 5lb 250ft 200C Magnetic Coil Winding $73.60

16 AWG Gauge Enameled Copper Magnet Wire 5lb 625ft 200C Magnetic Coil Winding $73.09

27 AWG Gauge Enameled Copper Magnet Wire 5lb 7850ft 200C Magnetic Coil Winding $71.73

13 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 315ft Magnetic Coil Winding $71.53

15 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 500ft Magnetic Coil Winding $71.36

12 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 250ft Magnetic Coil Winding $70.19

25 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 4975ft Magnetic Coil Winding $69.68

14 AWG Gauge Enameled Copper Magnet Wire 5lb 395ft 200C Magnetic Coil Winding $68.63

13 AWG Gauge Enameled Copper Magnet Wire 5lb 315ft 200C Magnetic Coil Winding $67.16

11 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 198ft Magnetic Coil Winding $61.87

10 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 157ft Magnetic Coil Winding $61.78

11 AWG Gauge Enameled Copper Magnet Wire 5lb 198ft 200C Magnetic Coil Winding $61.06

10 AWG Gauge Enameled Copper Magnet Wire 5lb 157ft 200C Magnetic Coil Winding $61.05

500′ Roll 20 AWG Copper Magnet Wire Winding Tesla Radio $59.95

100′ Spool of 12 AWG Magnet Wire Turning / Winding $59.95

500′ Spool of 20 AWG Magnet Wire Turning / Winding $59.95

27 AWG Gauge Enameled Copper Magnet Wire 5lb 155C 7850ft Magnetic Coil Winding $59.30

18 AWG Gauge Enameled Copper Magnet Wire 200C 5lb 995ft Magnetic Coil Winding $57.26

1KG ENAMELLED COPPER WINDING WIRE / MAGNET WIRE 0.45mm $25.01

1KG ENAMELLED COPPER WINDING WIRE / MAGNET WIRE 1.80mm $25.01

1KG ENAMELLED COPPER WINDING WIRE / MAGNET WIRE 0.355mm $25.01

Winding Wire Questions

Everything You Need To Know About Windings for 3-phase stators

On motorcycles and ATV stators the copper windings serve the most substantial role. These windings are set to transform the changes in magnetic field into electricity in an efficient manner. Key issue in designing these copper windings is the generated current also warms up the copper wire itself as the wire behaves like a resistor.

Number of turns

There are a few crucial variables in stator winding design. Firstly you have the amount of turns of copper wire per pole. Secondly there is the wire size, and thirdly the winding configuration. When we increase the number of turns per pole the output voltage goes up, while the output current drops a bit. But put too many turns on the poles and the resistance of the extra windings causes the temperature to rise dangerously. Choosing too small a wire size drops the output, but also increases resistance which can raise the temperature too. In the event you increase in wire size too much then you could be saddled with a peaky and very high output that can result in the winding to fail as a direct consequence of overheating.

Y or DELTA configurations

You can connect three phase systems in two manners: in Y, or in Delta. The Delta configuration looks like this: there are three windings, each with two ends (as they are three individual pieces of copper wire with a beginning and an end) Connecting two of the ends of two windings to one output and doing this times three connects the winding in Delta, which looks like triangle.
You may as well connect three ends with the three copper wires together, and feed each other copper wire end into an output wire. This configuration looks like a star, or a “Y” which is referred to as a Y-configuration.

Each configuration has its own merits for use in motorcycle and ATV stator applications. For lower power or lower average rpm applications usually the Y-configuration is used, and for higher power or higher rpm applications the DELTA configuration is more prevalent.
Windings in DELTA connection typically use a smaller copper wire size and use more turns per pole in comparison to Y-connected windings. For some applications a Y-connected stator can be replaced with a well configured DELTA-connected stator to raise output.

Chasing the compromise

As in everything you will find there’s a golden compromise in each design that’s driven by the specific needs of the vehicle, average engine rpm, diameter of the stator as well as magnet strength of this rotor.

Why does a stator typically fail

When a stator winding fails initially it is not the copper wire that fails, instead the generated heat within the winding causes the insulation around the wire to collapse and short the outer layer on the windings. 

Coatings used on copper winding wire

As the windings must be stacked on top of each other they are unable to electrically make contact externally. Hence the insulation layers around the copper wire are super critical. Normally copper wire has multiple layers of clear insulation, and for motorcycle stator applications this insulation needs to be oil resistant and also rated to resist a very high temperature before it in time breaks down.
Standard copper winding wire is rated at 160-170 degrees Centigrade, extreme temperature rated wire is with a rating of around 180 degrees Centigrade and also highest rated wire uses insulation that is rated at around 200 degrees Centigrade. 
The quantity of coatings that are used determines some of the insulation qualities. The greater outside diameter also can mean that too few winding turns will be wound on the stator poles for maximum output.
The type and material of the insulation coating used determines the maximum winding operating temperature. Superior quality winding wire that is rated at a high temperature therefore is far more expensive than standard wire.

Lead wires between winding and connector

The lead wires must be of top quality stranded wire, having an insulation which does not melt with rising temperature since these output lead wires get surprisingly hot during normal use. Also a superb connection between lead wires and copper winding wire is important for very long term reliability.

Which coatings can be used to protect the winding

A outside protective layer is used around the windings which helps prevent any movement in the copper windings. This is certainly essential to longevity.

About the Author

Get more information online about motorcycle stater deals as well as helpful tips and tricks for choosing and installing motorcycle parts at ElectroSport.com.

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