Due to their small size and high precision requirements, the rotor winding process for micro and miniature motors (such as brushless DC motors, brushed motors, and stepper motors) directly affects the motor’s electromagnetic performance, operational smoothness, and service life.
⚬ Compact Space with Extremely High Slot Fill Rate Requirements
The space within the rotor slots of micro and small motors is extremely limited. To maximize the motor’s power density and efficiency, as much enameled wire as possible must be packed into the tiny slots. This requires extremely precise wire layout, with no tangled or overlapping wires.
Coils Winding for Micro and Small Motor Rotors | WIRESUN Presents
⚬ Fine Wire Diameter and Low Mechanical Strength
Micro motors typically use extremely fine enameled copper wire (with diameters often ranging from 0.02 mm to 0.5 mm). This type of wire has extremely low tensile strength and is very fragile; even the slightest mishandling can cause wire breakage or excessive stretching.
⚬ High Dependence on Dynamic Balance and Symmetry
Micro motors often operate at high speeds (ranging from several thousand to tens of thousands of revolutions per minute). During winding, the number of turns, arrangement, and weight distribution of the coils in each pole (each slot) must be highly consistent. If the winding weight is asymmetrical, it will cause poor dynamic balance in the rotor, leading to severe vibration and noise.
⚬ Special Requirements for Winding Equipment
Since manual winding cannot guarantee the precision and consistency required for fine wires, micro-motors rely heavily on automated equipment. Fly-fork winding machines (for brushed rotors/outrunners) or needle-type winding machines (for internally wound stators/specific rotors) are commonly used to achieve high-precision three-dimensional spatial trajectory movements.
About WIRESUN
Founded by a management team with over 30 years of hands-on expertise in coil winding, WIRESUN has grown into one of Dongguan's trusted precision coil manufacturers. We provide OEM and ODM custom coil winding services, producing air core coils, bobbin coils, and special-shaped coils, along with coil winding machines and wire tensioners.
Contact us:
sales@wiresun.com ｜ +86-186 2185 7689 (Bi Danfeng)