All About 3-Phase motorcycle and ATV windings | ArticleFinish.com

When talking about stators for motorcycles and ATVs arguably the most important part is the copper winding that is wound on it. Changes in the magnetic field lines are changed into electricity in these windings and it needs to be done efficiently. The design challenge is to do this without heating up the windings themselves excessively due to the power running through.

Number of turns

There are several significant variables in stator winding design. Firstly there is the quantity 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. When you go up in wire size too much you may be tied to a peaky and extremely high output that can result in the winding to fail as a result of overheating.

Configuration options in three phase windings

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.
It is also possible to connect three ends on 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? and is referred to as a Y-configuration.

There are advantages to both configurations. For high rpm and high power applications typically a Delta setup is used. The Y setup offers better low rpm power and thus is more suitable in lower rpm applications.
Windings in DELTA connection typically use a smaller copper wire size and make use of more turns per pole when compared with Y-connected windings. For some applications a Y-connected stator may be replaced with a properly configured DELTA-connected stator to elevate output.

Chasing the compromise

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

Stator failure

If a stator winding fails initially it?s not the copper wire that fails, instead the generated heat inside the winding causes the insulation around the wire to break down and short the outer layer of the windings.

Which coatings are used

Given that the windings really need to be stacked on top of each other well they are not able to electrically make contact on the outside. Therefore the insulation layers surrounding the copper wire are very important. Normally copper wire has multiple layers of clear insulation, as well as motorcycle stator applications this insulation really should be oil resistant and also rated to withstand a higher temperature before it breaks down.
Standard copper winding wire is with a rating of 160-170 degrees Centigrade, extreme temperature rated wire is rated at around 180 degrees Centigrade as well as the highest rated wire uses insulation that is rated at around 200 degrees Centigrade.
More insulation layers round the copper mean better insulation, but which means a considerable outside diameter for the same copper conductor size which does not help output at all. Note also that thicker wire limits the amount of turns that can fit on a pole, potentially preventing an ideal wire configuration due to lack of winding space.
The type and material of the insulation coating used determines the maximum winding operating temperature. Top quality winding wire that?s rated at a high temperature therefore is much more expensive than standard wire.

Wire lead connections

The lead wires has to be of high quality stranded wire, having an insulation that won?t melt with rising temperature as these output lead wires get surprisingly hot during normal use. Additionally a superb connection between lead wires and copper winding wire is very important for very long term reliability.

Which coatings can be used to protect the winding

To enhance longevity manufacturers typically apply an outside coating about the copper windings. This coating prevents motion in the wires that can cause chafing and insulation failure.

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

Save this article as PDF file ---->

Source: http://articlefinish.com/all-about-3-phase-motorcycle-and-atv-windings/

camel gis caa make it or break it okc brad womack and emily maynard crush