THREE PHASE AC MACHINE WINDING

OBJECTIVES:

The student must be able to:

1. Perform the operation steps in
rewinding.
2. Form the coil to the rewinding
board.
3. Rewind three phase
induction motor.
 Stator winding
Laminated stator core
Enclosure
Stator winding

Stator winding End-winding

(overhang)
Introduction
• The Armature winding of a machine is defined as an
arrangement of conductors' design to produce emfs by
relative motion in a magnetic field.
• Electrical machines employ groups of conductors distributed
in slots over the periphery of the armature.
• The groups of conductors are connected in various types of
series-parallel combination to form Armature winding.
• The conductors connected in series so as to increase the
voltage rating.
• They are connected in parallel to increase the current
rating.
• Some of the commonly used terms associated with windings
are as follow:
Common Terminologies associated with ac windings
Conductor:
• The active length of a wire or strip in the slot.
Turn:
• A turn consists of two conductors separated from each other by a pole pitch or
nearly so, and connected in series as shown in fig.(a)
• The conductors forming a turn are kept a pole pitch apart in order that the emf
in two are additive to produce maximum resultant emf.
N S

Conductor

Conductor

Pole-pitch

a) Single turn coil

Coil: A coil may consist of a single turn or may consist of many turns,
placed in almost similar magnetic position, connected in series.
Coil-Side: A coil consists of two coil sides, which are placed in two
different slots, which are almost a pole pitch apart.
 Pole pitch: The peripheral distance between identical points on the
two adjacent poles. It is always equal to 1800 electrical.

N S N S

Conductor

Conductor

Coil side
 Coil span or coil pitch: The distance between two coil sides of a
coil. It is usually measured in terms of teeth, slots or electrical
degrees.
 Chorded coil: If the coil span is equal to the pole pitch, then
the coil is termed as a full pitch coil. In case the coil pitch is less
than pole pitch, then it is called chorded, shorten, or fractional
pitch coil.
• The connections joining the conductors form the end connectors or in
the mass, the overhang or end winding.

Overhang
C

B D
Coil-sides

Pole-pitch

Single turn coil

TYPES OF AC MACHINES WINDINGS
 They are two basic physical types for the windings. They deal
differently with the mechanical problem for arranging coils in
sequence around the armature.
 The two types are:
1. Single layer winding and
2. Double layer winding
 1. SINGLE LAYER WINDING
 Fig a below shows an arrangement for a single layer
winding. In this type of winding arrangement one
coil side of a coil occupies the whole of the slot.
 Single layer winding are not used for machine
having commutator. Single layer winding allow the
use of semi-closed and open types of slots.

Coil
side

Semi-closed slot Open slot

 2. DOUBLE LAYER WINDING
 The double layer winding have identical
coils with one coil side of each coil lying
in top half of the slot and the other coil
side in bottom half of another slot
exactly or approximately one pole pitch.
 Each layer may contain more than one
coil side in case large numbers of coils
(a)
are required (fig c).
 fig c shows the arrangement wherein
there are 8 coil sides per slot. Open slots Top coil side
Coil
sides Top

are frequently used to house double

(top layer) layer

layer windings. Bottom coil side

(Bottom layer)
Bottom
layer

(b) (c)
NUMBER OF PHASES AND PHASES
SPREAD
An ac winding, meant to be user for a 'm' phase system,
should produce emfs of equal magnitude in all the phase.
These emfs should have identical waveforms and equal
frequency.
Their displacement in time should be y =2/m electrical
radians.
This is obtained by having similar pole phase groups (a pole
phase group is defined as a group of coils of a phase under
one pole) and arranging the groups to have an effective
displacement of y =2/m electrical radians in space.
Consider the case of a 12-slot armature having 2 poles A
and wound for three phases as show in fig below (a). If
1
12 2

the flux density wave shape is considered sinusoidal, 11 e12

e1
e2 3
the emfs of the conductors in the slots can be C e11
e3

represented as a phasors displaced from each other by 10 e10 e4 4

an (electrical) angle, as shown in fig(a). e9 e5

9 e8 e6 5
e7
P 
s   radian 30 8
S 6 7
6

If the winding is divided into three groups (one for each B
phase) spread over two pole pitches, the electrical Fig.(a) e4
displacement in space between the groups is 2/3 e3

electrical radian or 1200 electrical. e2

EA

Each phase is located in four consecutive slots and so e12

EC
e1

the phase spread is 4 x 300 = 1200 electrical.

1200

1200
e11 e5
If the conductors in the slots are connected as per the e10 e9 120 0

phasor diagram fig (b) , the summation of conductors e6

emfs would give three emfs displaced 1200 in time e7

following a phase sequence of ABC in time. The space EB

sequence is also ABC.
e8

Fig.(b)
TYPES OF SINGEL LAYER WINDINGES

• The three most common types of single layer windings are

1. Concentric windings ( Unequal coil span)
2. Mush windings (equal coil span)
3. Chain windings (equal coil span)
 End-windings of stator winding

Concentric type

Mush type
 MUSH WINDING
 This winding is very commonly used for small induction motors having circular
conductors.
 This is a single layer winding where all the coils have same span. Each coil is
wound on a former, making one coil side shorter than the other.
 The winding is put on the core by dropping the conductors, one by one into
previously insulated slots.
 The short coil sides are placed first and then the long coil sides. The long and
short coil sides occupy alternate slots.
 Sometimes it is known as a basket winding.
Coil-sides of mush winding arrangement inside the
slots
 CHAIN WINDING
• In all aspects, this winding is similar to that of mush winding except that both
coil sides of a coil have equal length and diamond shape.

1 3 5 7

2 4 6
 Example # 1 : on Chain Winding
Using the data and the solution of Example #1, construct the single-layer chain winding diagram.
Given data
S=12; p=2;m=3; a=1; type= Chain
Solution
a) The number of coil groups, K
P 2
K 3  3  3 i.e. there is one coil group per phase
2 2
b) The number of slots per pole per phase, q
S 12
q  2 i.e. there are two coils in a group
m p 3 2
c) Coil pitch

S 12 Full-Pitch
YS   6
p 2

This is an even number and hence the winding is not possible with an even coil span . There fore , it is
shortened by one slot and a coil span of 5 slots is used.
 d)The electrical angle, 

 180 P 180 2 360

e) The angle between adjacent slots, 

360
  30
S 12

f) The distance between the beginning of each phase, 

120 120
  4 slots
 30 

g) If the beginning of Phase A is slot 1, then the beginning of phase B

is slot 1+=5 and the beginning of phase C is slot 1+2=1+8=9
Phase sequence
A
C’
B’ 600

C B

A’

1 2 3 4 5 6 7 8 9 10 11 12

A A C’ C’ B B A’ A’ C C B’ B’
Connection diagrams
Phase C
Phase A Phase B
B C
A

+5
2 7 R 6 11 R 10 3 R

1 +5 8 L 5 12 L 9 4 L

A’
B’ C’
10 3

8 12 1
5

1 3 5 7 9 11

2 4 6 8 10 12

8 5
12 1
10 3

A C’ B A’ C B’
CONCENTRIC WINDING
 Three-phase concentric winding consists of coil groups laid in the slots
so that all the coils of each group are concentric.
 That is, the coil with the smallest slot pitch is surrounding by the coil
with the next larger slot pitch and so on to make up a coil group.
 Each coil consists of several turns and the cross-over from one coil to
the next is indicated by a short slanted line (jumper).
 In order to construct the diagram for a winding, the following date
must be known:
S - The number of slots in the stator
P – The number of poles
m – The number of phases
YS – The pitch of the winding
 The pith of the winding is determined by the formula
S
YS 
P Coil-sides
 The pitch is the distance between two sides of a coil
expressed as the difference between the numbers of the
slots in which the sides lie. Pole-pitch

 Another important value of the winding of ac machines is

the number of slot per phase per pole denoted by the letter
q. It can be determined by the formula A coil-group with 3-coils
S
q
P m q

 Sometimes q is called a pole-phase group is defined as a

group of coils of a phase under one pole.
Y1
1 12
Y2
2 11
3 Y3
 The number of slots per pole per phase in concentric 10
Jumper

winding can be seen directly from the diagram. It is equal to

the number of coils in a coil group.
Start Finish
(S) (F)
CONNECTTNG COIL GROUPS INTO PHASES
As soon as all the coils have been laid in the slots, the coil groups are connected in to
phases.
Each group is provided with two leads for the start and finish of the group.
The total number of leads is therefore twice the number of coil groups.
A stator winding must have six leads brought out to the terminal panel these leads
being the beginnings and ends of the three phases.
All the reaming leads must be interconnected in the respective phases with in the
winding.
It is now necessary to decide in order to determine the beginnings and ends of each
phase.
The distance between the beginning of the phase and the distance between the ends
of the phase must be equal to 120 electrical degrees.
Any slot can be chosen as the beginning of the first phase.
The coil groups in each phase should be interconnected by joining there unlike leads,
i.e. start to finish, or finish to start.
 Example#2: on concentric winding

Given data
S=24; p=4;m=3; a=1; type=Concentric
• Solution P 4
a) The number of coil groups, K K 3  3  6
2 2 i.e. there is two coil groups per phase

S 24
b) The number of slots per pole per phase, q q  2 i.e. there are two coils in a group
m p 3 4

c) Coil pitch S 24 Full-Pitch ( average pitch)

YS   6
p 4

The shorter coil pitch = YS-1=6-1=5

The larger coil pitch = YS+1=6+1=7
 180 P 180 4 720
d) The electrical angle, 
720
   30
e) The angle between adjacent slots,  S 24

120 120
f) The distance between the beginning of each phase,    4 slots
 30
 Phase sequence
A
C’
B’ 600

C B

A’

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

A A C’ C’ B B A’ A’ C C B’ B’ A A C’ C’ B B A’ A’ C C B’ B’
connection Diagrams

Phase A Phase B Phase C

A B C

1 +7 8
5 12
I 2 +5 7
II III 9 16

6 11 10 15

13 +7 20 17 24
IV +5 19
V VI
21 4
14 18 23 22 3

A’ B’ C’
 PROCEDURE FOR CONSTRUCTING OF
CONCENTRIC WINDINGS

Data: S= 24, P = 4, a = 1, q = 2, K = 6

1. Draw 24 vertical lines and number them

1 3 5 7 9 11 13 15 17 19 21 23

2 4 6 8 10 12 14 16 18 20 22 24
Coil Groups of Phase A
2. The first and second slots will be occupied by left-hand sides of the first coil group
of phase A.
3. Leave four, or 2q slots free for other two phases occupy slots 7 & 8 with the right
hand side of the first coil group.
4. Next to it will lie a second coil group of the same size which occupies slots
9,10,15,16.

1 3 5 7 9 11 13 15 17 19 21 23

2 4 6 8 10 12 14 16 18 20 22 24
Coil Groups of Phase B
 In order to find, where the second phase (B) should begin, it is necessary to know the angle
between slots in electrical degrees.
=180.P = 180.4 = 7200 – Electrical degree
 The angle between adjacent slots, 
720
   30
S 24
 The distance between phase beginnings will have

120 120
   4 slots
 30

1 3 5 7 9 11 13 15 17 19 21 23

2 4 6 8 10 12 14 16 18 20 22 24
Coil Groups of Phase C

21 4
22 3

1 3 5 7 9 11 13 15 17 19 21 23

2 4 6 8 10 12 14 16 18 20 22 24

22 3

21 4
Current direction

N S N S
1-6 7-12 13-18 19-24

21 4

22 3

1 3
N 5 7 9 11 13 15 17 19 21 23

S N S
2 4 6 8 10 12 14 16 18 20 22 24

22 3

21 4
Phase A – Coil groups interconnection

21 4

22 3

1 3
N 5 7 9 11 13 15 17 19 21 23

S N S
2 4 6 8 10 12 14 16 18 20 22 24

22 3

21 4
Phase B – Coil groups interconnection

21 4

22 3

1 3
N 5 7 9 11 13 15 17 19 21 23

S N S
2 4 6 8 10 12 14 16 18 20 22 24

22 3

21 4
Phase C – Coil groups interconnection
21 4

22 3

1 3
N 5 7 9 11 13 15 17 19 21 23

S N S
2 4 6 8 10 12 14 16 18 20 22 24

22 3

21 4
Terminals
21 4

22 3

1 3
N 5 7 9 11 13 15 17 19 21 23

S N S
2 4 6 8 10 12 14 16 18 20 22 24

22 3

21 4

A C’ B C A’ B’
 21 4

22 3

1 3
N 5 7 9 11 13 15 17 19 21 23

S N S
2 4 6 8 10 12 14 16 18 20 22 24

22 3

21 4

A C’ B C A’ B’
DOUBLE LAYER
Double layer windings differ from single layer winding mainly on the
following main points:
Each slot is occupied by the side of two coils and each coil is arranged to form two
layer round stator.
One layer of the winding lies in the bottom half of the slots and the other in the top
half of slots.
Unlike the concentric winding double layer winding consists of identical coils all of
the same shape and pitch.
In a double layer winding, the coil pitch is the distance between the top and the
bottom sides of the coil expressed by the number of slots spanned or by the coil
sides or by the number of slots occupied by each coil side.
A coil pitch may be full or fractional. Majority stator windings use a fractional pitch
because
The amount of copper used in the overhang (end winding) reduced and hence a
saving on copper, and
The magnitude of certain harmonics in the emf and also mmf is reduced.
The full pitch is determined by
S
YS 
P
Usually the full pitch is shortened by one-sixth i.e. for example if the full
pitch is 12 a fractional will be 10.
Since the coils are wound with a continuous length of wire there are no
connections between turns.
Double Layer Three phase windings
The main value characterizing the two layer winding is the number of slots per pole
per phase.
S
q
P m

By looking double layer winding externally, it is not possible to determine q.

The total number of coils in two layer winding is equal to the number of slot since
each side of a coil occupies one half of a slot which is equivalent to occupying one
full slot per coil.
In order to avoid making solder joints between coils, several coils, depending upon
slots per pole per phase, are generally wound from a single length of wire in to full
coil group.
The number of coil groups per phase is a equal to the number of poles the whole
winding. That is K
P K mP
m
This is, twice that in a single-layer winding.
Rule for double layer windings
The coil groups should be connected to each other by joining the leads
of like polarity i.e. the finish of one group to the finish of the next group
and the start of one group to the start of the next group.
 Example # 3: on double layer winding

Given data
S=12; p=2;m=3; a=1; type=Double layer: the pitch shortened by one slot
• Solution
a) The number of coil groups, K
i.e. there is two coil groups per phase
K 3 P 3 2 6

b) The number of slots per pole per phase, q

S 12
q  2 i.e. there are two coils in a group
m p 3 2
c) Coil pitch
S 12
YS   6 Full-Pitch
p 2

Let us shorten the pitch by one slot and make YS = 5.

d) The electrical angle, 

 180 P 180 2 360

e) The angle between adjacent slots, 
360
   30
S 12
f) The distance between the beginning of each phase, 
120 120
   4 slots
 30 

g) If the beginning of Phase A is slot 1, then the beginning of

phase B is slot 1+=5 and the beginning of phase C is slot
1+2=1+8=9
Phase sequence
A
C’
B’ 600

C B

A’

1 2 3 4 5 6 7 8 9 10 11 12

A A C’ C’ B B A’ A’ C C B’ B’
Connection Diagrams
Phase A Phase B Phase C
A B C

I III
V
+5 +5
1 6' 5 10' 9 +5 2'
+5 +5
2 7' 6 11' 10
+5
3'

IV
+5
VI II
+5
7 12' 11 4' 3 +5 8'
+5 +5
8 1' 12 5' 4 +5 9'

A’ B’ C’
PROCEDURE FOR CONSTRUCTING
OF DOUBLE LAYER WINDINGS
 Draw 24 vertical lines to represent the two coil sides lying in each of the 12 slots. For each slot the full line
at the left hand side will represent a top a coil side and broken line at the right hand side a bottom coil
side.

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'
 The top part of slot 1 will be taken as the beginning of the first phase. According to the selected fractional
pitch, the conductor from slot 1 is now connected to that in the bottom coil side in slot 1 + 5 = 6’.

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'
 Since q = 2 i.e. each coil group will consists of two coils. The conductor must therefore leave the bottom of slot 6 to
enter the top of slot 2 and from there the bottom of slot 7. The lead emerging from slot 7 will be finish of the first
coil group.

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'
 Phase A
A

Phase A : Coil groups 1 +5

I
6'
+5
2 7'

IV
+5
7 12'
+5
8 1'

A’

1'
8

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'

1'
8
 Phase B

Phase B: Coil groups B

III
+5
5 10'
+5
6 11'

IV
+5
11 4'
+5
12 5'

B’

11
4'
8 12 1'
5'

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'

5'
12
1'
8
11 4'
 Phase C
C

Phase C: Coil groups 9

V
+5 2'
+5
10 3'

II
3 +5 8'

4 +5 9'

C’

10 3'
11 2'
4'
8 12 9 1'
5'

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'

5'
12
1'
8
11 4'
9 2'
10 3'
 Current direction
N S
1-6 7-12

10 3'
11 2'
4'
8 12 9 1'
5'

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'

N S
5'
12
1'
8
11 4'
9 2'
10 3'
 Current direction
N S
1-6 7-12
10 3'
11 2'
4'
8 12 9 1'
5'

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'

N S
5'
12
1'
8
11 4'
9 2'
10 3'
Phase A: Coil groups interconnection

10 3'
11 2'
4'
8 12 9 1'
5'

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'

N S
5'
12
1'
8
11 4'
9 2'
10 3'
Phase B: Coil groups interconnection

10 3'
11 2'
4'
8 12 9 1'
5'

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'

N S
5'
12
1'
8
11 4'
9 2'
10 3'
Phase C: Coil groups interconnection

10 3'
11 2'
4'
8 12 9 1'
5'

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'

N S
5'
12
1'
8
11 4'
9 2'
10 3'
 Terminal leads

10 3'
11 2'
4'
12 9 1'
8 5'

1 1' 2 2' 3 3' 4 4' 5 5' 6 6' 7 7' 8 8' 9 9' 10 10' 11 11' 12 12'

5'
12
1'
8
11 4'
9 2'
10 3'

A C’ B A’ C B’
PROCEDURE STEPS IN REWINDING AN INDUCTION MOTOR

[Link] data of the three phase induction motor

2. Stripping the winding to the stator slots
3. Insulating the stator slots
4. Winding the coils to the stator
5. Placing the coils to the stator slots
6. Connecting the stator winding
7. Testing the winding
8. Banding or lacing the coil
9. Baking and Varnishing

BY Tsegaye Alemu
Winding the coils..

• Manual winding machine

Special form for single or gang winding
END