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Old 04-21-2011, 09:18 AM   #1 (permalink)
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Anyone ever rewind a motor? (series wound DC)

I have an otherwise good motor that I burnt up a while back (over heated it). I was quoted $300+ to have it rewound at a shop, and thats just a bit too much for me. But, I wouldn't mind taking a crack at repairing/rewinding it myself if its possible. Has anyone ever done anything like this, or know of a good tutorial online, or just tips or info that might help.
Here are images of the damage:



This is the other side (180 degrees the other damaged area):

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Old 04-21-2011, 10:20 AM   #2 (permalink)
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Did the bars between windings get bent? They appear on an angle to the shaft.

This popped up searching "rewinding DC motor" on Youtube:



And there are a bunch of "suggestions" in the sidebar.
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Old 04-21-2011, 10:26 AM   #3 (permalink)
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Doh! In part 5 he burned up his rewound motor.

YMMV!

But it does appear there are more than a few vids of intrepid modders attempting this task.
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Old 04-21-2011, 11:14 AM   #4 (permalink)
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i've rewound small DC motors before, but none like that one. it's a daunting task either way though, should be relatively easy to find information online.
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Old 04-21-2011, 11:30 AM   #5 (permalink)
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I've had my starter rebuilt locally for like $70. How big is that motor?

The rc guys do this stuff a lot, on a smaller scale. Some ambituous types have rewound motors to suit different supply voltages as well (i.e. thinner wire and more turns for higher voltage supply, works the other way also).

http://www.eng-tips.com/viewthread.c...194110&page=94
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Old 04-21-2011, 11:39 AM   #6 (permalink)
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The motor is 7" in diameter and probably 8" long. Its rated for 24V / 64A. I was using for my electric riding lawn mower, but it proved a bit too small for the application (without additional cooling).
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Old 04-21-2011, 12:49 PM   #7 (permalink)
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we've had a few motors (farm applications) rewound locally. Not sure what it cost exactly for one off's since we have a large account with them, but I could look into for you if you want. Never been ambitious enough to try it myself, but it would sure be interesting to give it a try.

Most of what we have rewound are 10" motors that run belts in the chicken houses. I keep eyeing them everytime I'm back home...electric escort anyone? Maybe give it a better look once school is out.
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Old 04-25-2011, 10:08 PM   #8 (permalink)
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electric escort sounds great cant wait for that build
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Old 04-25-2011, 11:12 PM   #9 (permalink)
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MetroMPG, IIRC, the twist that you see is supposed to be there to make the rotation smoother. It has to do with the magnetic feild being pulled less like a pulse and more at an angle. They do the same things with generator windings.

Personally, it is WAY more dificult to rewind your windings yourself than have it done. It can be done, I've rewound one generator rotor( 4 pole) and never again. If you are going to try it yourself, before you buy any new wire, try unwinding it, by hand, trying not to chip any more of the laquer off the wire. Test some of the windings to make sure they are still good( no grounds or opens), some will be, and see if they are still good after you are done removing them. A meger is a good tool to have when attempting this. Of course, it can also be used to burn up windings as well.

Best of luck
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Old 04-26-2011, 10:24 AM   #10 (permalink)
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The whole world runs on smoke. Electricity is just another form smoke. Once you've let it out you'll never get it back in there.
But seriously rewinding that motor will prove to be a daunting task for someone with no experience. I don't say that to discourage you from learning something new by any means just know it's not as easy as it looks. You may beat $300 at a local rewind shop given the size of that one but not by much there is a lot of copper in there and the bars need to be dressed up. A good shop should replace the bearings and properly seat the brushes as well (not let them wear themselves into full contact with the commutator). Just out of curiosity what does the stator look like? Should you decide to attempt yourself keep it posted I would love to see your progress.

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