Cross-Section Optimisation in Home Appliance Motor Winding

In home-appliance motor windings the volumes are high and margins tight; small improvements therefore make a clear difference at annual scale. Within the project the diameter step, build grade and winding tension of the existing design were examined together.

The review found that the build grade in use was one step higher than the application required and that this lowered the fill factor. After evaluating turn voltage and mechanical stress during winding, a move to a lower build grade was recommended; a custom draw at an intermediate diameter step brought the winding height into the target range.

In winding trials with a pilot batch, no film damage or breakage was observed; the breakdown voltage and flexibility-adhesion tests under IEC 60851 met the acceptance criteria. After the change, a measurable improvement was achieved in copper consumption per winding and in winding scrap.