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 250G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 49SWG US $76.64 
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 100G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 49SWG US $31.53
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 1KG ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 49SWG US $197.46
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 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.040mm US $51.75
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 1KG ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 48AWG US $197.46
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 250G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 46AWG US $35.56
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 250G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.030mm US $76.64
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 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 48AWG US $114.57
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 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 49SWG US $114.57
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 100G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 46AWG US $18.88
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 1KG ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.030mm US $197.46
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 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.030mm US $114.57
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 250G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.040mm US $35.56
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 100G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.040mm US $18.88
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 1KG ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 46AWG US $90.00
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 100G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 48SWG US $18.88
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 250G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 48SWG US $35.56
|
 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 46AWG US $51.75
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 250G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 48AWG US $76.64
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 100G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 48AWG US $31.53
|
 1KG ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.040mm US $90.00
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 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 48SWG US $51.75
|
 1KG ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 48SWG US $90.00
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 100G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.030mm US $31.53
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 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.050mm US $31.01
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 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 46.5SWG US $31.01
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 1KG ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.125mm US $52.94
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 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 38 AWG US $31.01
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 250G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 38 AWG US $20.15
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 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 40 AWG US $31.01
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 500G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 44 SWG US $31.01
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 1.1 lbs ENAMMELED COPPER WINDING WIRE 42 AWG US $31.01
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 250G ENAMMELED COPPER WINDING WIRE /MAGNET WIRE 0.063mm US $20.15
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 1KG ENAMMELED COPPER MAGNETO WINDING WIRE 0.071mm US $52.94
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 1KG ENAMMELED COPPER MAGNETO WINDING WIRE 0.090mm US $52.94
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 1KG ENAMMELED COPPER MAGNETO WINDING WIRE 0.030mm US $197.46
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 500G ENAMMELED COPPER MAGNETO WINDING WIRE 0.040mm US $51.75
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Winding Wire
SUBMERSIBLE WINDING WIRE
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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