Retired electrician after 48 years. Installed hundreds of motors (400HP and less) and had never seen the fine details of how this process was done until now. Thanks for filling in a gap in an old man's knowledge.
@twerktospec glad he didn't entertain your ignorant comment but I will. Why would he lie about that? He even stated he worked on motors under 400hp. You realize people that work in these fields are real people, with TH-cam accounts and would likely have interest watching a video like this? Don't let your ignorant cynicism poison you.
@@twerktospecwhats left to prove? And why should he prove it to you? Some random dude on the internet 🤡 Installing 400hp motors (~300kW) is not that wild as you might think. 🤷🏼♂️
What one of you doesn't pretend to know everything like being we the people and not even close . Anti to arrogant jackasses pretend to know much in life deceivers of even self unknown to even self refuse correction refuse truth refuse justice refuse freedom if can't understand what protects freedom and justice exactly only could be anti and to arrogant pretenders of know blame all but self unknown to even self believe your own lies kill each other pretending to be the good smart one gotta stop them dummies vice versa dummies kill each other pretending to be the smart one . Sorry is starting to chap my ass someone said I like them many do many and I like none I understand exactly what I stand for . People nuts to me o skywalker Luke no Jedi actor I no TV fake ass I am the superman man of steel Fly's without wings connector the man of steel first and last beginning and end one and 99 born 100 like no other before . Liars pissing me off sorry just in spot started bitching lord Knows all o hear and cause of what Bitch about and blame all but self the one thing could fix all I can find
I’m having a Barlow 120v 1/4 hp ac motor from a “Genie” dual auger jewelry cab machine being rewound right now in Tacoma Washington. I’m from Louisiana and trained in physics engineering etc I want to know where to reference diagrams or schematics for motors. As an artist I want to learn. Thanks!
How nice to watch a decently made video with proper commentary rather than just monotonous music and proper views rather than just passing glimpses that some other videos have. Thank you for taking the time to film it.
Didn't show much at all,no showing coil placement or the coils being made nor how the amount of turns on the coil is calculated/counted. No new info or knowledge was gained by watching this that i didn't already know,wasted effort guys try a bit harder next time to be more informative in the technical side of the process and not the actual labour involved.
That was an excellent video. Before retiring many years ago, I was an electrical engineer at a magnox power station and have needed to have quite a few motors, small and large, rewound, due to various faults (including seawater ingress). Most of the original manufacturers were defunct so we had to rely upon the expertise and service of the specialists. Due to work load, I rarely had a chance to observe first hand the processes involved, so your video has been absolutely fascinating, and extremely well produced.
Have not wound a stator for 45 years but watching this brought back so many memories I can actually sense and feel a coil and wires in my hands, that's how good this video is. Thanks for posting.
I have been working at a Electric Motor repair/service workshop for just under a year, they’ve started me on my apprenticeship in Winding. Love these videos they really help me understand the trade.
I''ve been in the electric motor business for over 39 years and I enjoyed watching your video, and your attention to detail. It's also nice to see a clean shop, Great job to you and your crew.
This workshop is incredible! The amount of specialized tooling, there must be an absolute fortune worth of equipment at this plant. And the staff and management are very clearly no-nonsense operators. Nothing is being done half-arsed. Clearly a highly professional place with high standards. Refreshing to see, most places are backyard operations or just "minimum effort and resources to get the job done" kind of establishments. Keep it up, gents!
I know I really enjoyed it, I saw a vid where coils were wound by machine and It seemed simpler to just rewind the stator core by hand and that is how these crafted men are doing it, a very informative video.
I am a retired master electrician. this is the best video I’ve ever seen on the process of re-winding a motor thank you for sharing. I will use this to teach the grandkids On how the process it’s done
I work for the largest industrial electric motor manufacturer in the world. I have visited and studied many of our production facilities and their processes. Some of our customers are motor rewind shops. This one, in particular, appears to do a very thorough and professional job of rewinding this motor. Their process is very similar to the way our production process works on motors in this size range, with minor exceptions for special tooling, devices, guide fixtures, and some robotics in smaller motors for more repetitive processes. Very fine job, indeed!
@@FrederSnorlax depends on the motor. High production motors are often wound and inserted by automated machinery suited to the task. Larger frame, specialty, and lower production motors are indeed hand wound.
Jeez. I work in the offshore industry in the North Sea and I can literally see hundreds of these motors of various sizes all over the place every week, especially on the larger assets. I've heard of motor rewinds but never realised the amount of effort and skill involved in their construction. When new (or refurbed) motors arrive, they sometimes sit about for a while and you can get up close and it always surprises me that no matter how large they are, you can always turn the motor with one hand on the output shaft without any effort. Amazing.
The Volunteer Army Ammunition Plant or what we called the dynamite factory, used to be located in Chattanooga, TN. They made all the TNT use in the Korean and Vietnam war. There were huge air compressors to supply the whole site. The motors were large, slow-speed devices that ran on 4130 volts, 3 phase. I have photos of my friend Jerry Brown who I described above, standing upright in a stator, reaching over his head pushing windings into slots. We pumped varnish into the slots and spray-saturated the end turns. The bake-out oven affair we built over the motor was clever and large. It got the job done. If I recall correctly, those motors ran at 360 RPM and were synchronous motors with wound rotors and slip rings. The field winding could be over-excited to cause the motor to provide leading VARs to offset the lagging VARs induction motors made before the lagging VARs could reach the metering system and cause a low power factor charge. Fun times.
Your care and professionalism shows in not only your videography but in the quality and attention of all of your team members through the rebuild process.
I am not in your country nor do I have a need for large motors to be rewound but if I did I would entrust your company and excellent standards that you've shared with us. I appreciate you sharing your wisdom and nod to you for a job well done.
Having worked in the power industry for a long long time I have sent motors away for rewind and got a nice shiny one back this is a great explanation of how it is done. Unusual to have a technical guy able to explain the process so clearly.
Now I know why, if you take smaller motors to a shop, they often say it will cost more to rewind than to buy new. That's a good bit of work involved. Thanks!
I worked at KBZ Electric in Ashland, Ohio for awhile. I had the distinct privilege of helping the Master motor tech Greg Tinkey rewind a motor just about like this one. I still have one of the old bearings from that motor. It was quite the experience. I will always be grateful to Greg and KBZ for the experience. Thank you for the memory jog. Art from Ohio
Bloody fantastic, what a company. I work offshore globaly on deepsea in situ drilling. This to me has far more appeal. Places like India and different counties in Africa do the same, just without the toralences and machines. So good to watch. Great British company well done.
In india we have started using same equipment for tolerances for large motors 50KW and above For smaller motors the extra cost in testing is avoided because in practice the rewinded motors do operate risk free for 2-3 years and except full winding loss/burnt most repair shops provide very cost effective rewinding. GBP30 -50 per rewinding event that occurs once in every 4-5 years for the motors when they run on higher loads than recommended
Thanks for that video, I left the motor rewind trade 40 years ago having had a 5 year apprenticeship and then 6 years as a skilled winder. Most things haven't changed much although we wouldn't have done the initial tests, well we didn't have the equipment to do them, also dread to think of the damage we did to the lampack heating up with gas torches to strip the old windings, also no VPI back for us back in the 70s and early 80s varnishing was just running the varnish over either end and through the core before into the oven overnight. Great video and certainly brough back a good few memories, can almost smell the varnishes and the odour of burnt out windings on a motor in for repair. Happy to have done it for 11 years, equally happy that I changed to a career that let me retire before I was 60. Thanks for posting.
I was a motor winder for many years for GE. I've been retired for 11 years. This video brings back good memories. My last several years with GE I was certified in low, medium and high voltage switchgear and transformer testing. I used a Doble test set for the transformers
Thankyou very much for sharing this with us. I use electric motors for a variety of jobs, and this gives me another valuable insight into how these work. Kind regards, and greetings from Africa.
Excellent, I used to rewind Electric motors but the process which I saw explained by the gentleman is fantastic. I am impressed, thank you for uploading this video.
50 years ago I worked for C & H Rewinds in Farnworth near Bolton. In those days we used a hammer and chisel to cut off the crown, overnight in a big oven to soften the varnish, then pull the coils out with the use of a big crow bar. The workshop was always very hot and full of smoke. Then we had to wind the new coils by hand on formers hand cut out of plywood.
Really well demonstrated and articulated video! Anyone wanting to know the full process of what goes in to rewinding a motor should appreciate this! Thanks.
I did my electrical apprenticeship as a rewinder 50 odd years ago, then became a linesman LV and HV/cable jointer LV and HV then Switching Operator LV and HV up to full Switch Yard/Transmission voltages (220kv) and now a retired pensioner. Practices and materials have definitely changed over this time!
This was a very interesting video. I once attended church with a fellow who worked at a motor rewinding factory. Also, my brother worked at the "Electric Shop" for U.S. Steel in Birmingham, Alabama (USA) where they rewound a lot of motors. Finally, my father-in-law worked at Air Reduction Co., a supplier of oxygen for that same U.S. Steel plant. To make the oxygen and other gasses, they used many massive electric motors. The amount of electricity used was so great that the Alabama Power Company had to run a special line direct from the hydroelectric plant for several miles to Air Reduction Co. which was their largest customer. Having so many friends and relatives in this business, it was exciting to watch you explain how these huge motors are maintained. Thank you.
I’m an offshore elektromechanic. I work for a large offshore and dredging company on a 150m long hopper dredger. We have had a few sent for rewinding. My boss is a 68y old Croatian guy with 50y behind his belt. He started out in a company that builds cabinets, rewinds motors and transfo’s etc. I also sidehustle in a similar company, its beautiful to see the motors when they are freshly done. I hope to learn it myself over time from these oldtimers that work there. Some of them have been doing that for 30-40y now. Its a trade in its own, an art even. Great video! I love it
This excellent video answered most of my long held questions about how these types of motors get rebuilt. Truly professional and skilled craftspeople are needed for this type of trade.
That was the best video I've ever seen on a rewind job. I never knew a motor had so many tests to pass. Skilled craftsmen involved here. That explaines why the job can get expensive. 3 yr warranty besides. Thank you for showing this video
Thank you for this video. I have used many 3 phase squirrel cage motors in machine fabrication over the years without properly appreciating their intricacies. One machine installed in Indonesia was set up for 440 volt 3 phase which I was assured was the power they were using. Upon arriving half way around the world I discovered their power was in fact 380v 3 phase. A little connection alteration and we were back in business. The reserve amperage capacity of these motors (and our control wiring) was very much appreciated.
Nice to see british engineering isn't dead. We have so many old WW2-era lathes and machines here in Australia from the UK, it's nice to know you guys are still able to take pride in your workmanship.
I’m an electrical engineer by education but I am really more of a navigation and guidance algorithm guy by work experience. I just wanted to say that I found this fascinating and informative. I especially enjoyed the part where the windings are mechanically constrained to prevent movement under start/stop loads. Well done!
I feel like this is a factory tour my dad would have taken me on as a kid, and I would be staring at the floor. And now I could watch this stuff all day! Excellent narration too.
We used to use yourselves when I worked at Michelin tyres in Stoke. We had a 120kw motor that burned out while I was on a night shift and we removed it and contacted you for a 24hr rewind. Sure enough when I was in on the next night, it turned up. We fitted it and it lasted about 30 minutes before it started blowing fuses. No fault of yours, it should have been wired in delta and our sparky wired it in star! Anyway we took to off again, sent it back. Next night shift we refitted it and guess what, our spark did the same again, needless to say he was moved to another department very quickly after that
This brought back some memories as a youngster wanting to rewind a Lucas dynamo from an old motorcycle. I visited the local rewind shop asking for enameled wire, insulating paper and varnish. The owner was a bit surprised having a young dude interested to tackle this kind of job. Anyway he asked if i would be interested in a job as rewinder? I was still studying electronics so politely refused. Thanks for showing the whole proces. Back in the days we didn't had youtube. Reading books was the way to learn.
Great video ! I wish I could see how the new windings were actually put in. That seems to be the hardest part and maybe see how they are actually made. Thanks for showing us your amazing work. Tell all the guys thanks !
@@colincunningham1902 I had a 35KW generator get rewound in Egypt. Basically the same thing. It worked on my boat after that for 5 years before I ended up selling the boat. And as far as I know it is still working year later. So you would be surprised. Although; it is a hit and miss. Another guy I know had a full rewind and it didn't last a week. But in places like ours, sometimes it is a matter of availability. Also, rewinding can cost a 50th of a new purchase. So it also depends on economics.
I really enjoyed this video. I helped my dad rewind motors in the 1960’s. I’m impressed by all the technology used. Most of what you do is still the same. Thanks From Georgia in USA
I rewind motors at work (among other things). It's just a really nice feeling when it runs as intended in the testing area, knowing that this motor spinning there, putting out power well beyond human capability, you're the one(s) who made it so it does that.
Well, this is trully excellent.. You are one of probably really a few people from company managements that I've seen, who really is not worried about going into workshop and smear his ironed shirt, because that is just core of the work which You are doing. And what's more, You really understand and enjoy this work. This thing made my day, more people like this!
Well you've made my day with that comment, thank you. The workshop is where I started at a young age (about 9) with a brush in my hands. I do love the stuff we do and I do get plenty of shirts dirty too.
I used to work in a motor repair shop. It was dirty, the people were crude. Just a disgusting place to work. Suffice to say I did NOT stay there long. Glad to see there are shops that do it the right way. Thanks for the video.
Old rewinder here, low tension, high tension, ship board armatures, bar wound, commutator rebuilds. Traction motors. I think Miss the trade, unfortunately mostly a dead trade now. Used to rewind, single phase motors on the weekend for beer money. Good video.
There's a resurgence Kezza, we've got four apprentice winders with us right now. Electric vehicle and wind industry is where we've seen the industry turn around.
In 1975, I met a man named Jerry Brown who would become one of my best friends. He had just left a large motor repair shop and opened Jerry's Electric Motor Service in Cleveland, TN. Over the rest of my career as an engineer, I moonlighted for Jerry and learned all about winding motors. Jerry had an encyclopedic knowledge of motors. He prepared a 3X5" box of flip-cards for my use. To save money, I designed and built him a core loss tester and a surge tester, copying what I found in a Baker manual. I also designed a pneumatic winding puller for after the bake-out. It had both a hook that could be looped under a winding and a pair of pliers with chains welded to each handle. The more the physical resistance, the tighter the grip. Most windings came out with the hook. I also did repairs on industrial electronics such as VFDs. I am surprised that you didn't show the coil winding machine and the process, for I found that most fascinating. Also that you wound each coil separate with all the brazed connection. We wound all coils in a string with a single wire so the only brazed joints were the exit leads. A handy thing for people to know is the use of Sil-Phos as the brazing alloy. This alloy is self-fluxing so no external flux is needed. I use it for refrigeration for the same reason. I lost Jerry in 2022 to lung cancer. A lifetime cigar smoker. Part of my reason for writing this is to memorialize Jerry. All in all, a very interesting video. Thanks. John
It's a delight to see work being done to a high standard these days. Great to see serious young men learning a skilled trade. I have new hope for the future. Good luck, and God Bless.
Absolutely fascinating. The presenter explains things very well and it looks like a very professional operation. With all the handwork involved I now understand why rewinds are so expensive!
Oh man. I used to build these motors from scratch for BAE Systems, as well as repairing and refurbishing old ones. Pulling these things apart by hand was such hard work, lol. Great video.
I walked through a westinghouse motor and transformer production line and saw how they pulled the whole winding into each slot using a hydraulic cylinder hook. It was cool to see it done manually, since each motor is different, where theirs was a production line... Thanks for all the details and answered questions I've wondered about on motor rewinding!
Wonderful video. I also appreciate the talking and explaining instead of music. The video was the perfect amount of content without getting too technical.
Things brings back memories - I had a summer job in the 60's, for a Westinghouse shop in Swastika where we did this - less steps but the same basic idea. A dirty job, especially getting the old burnt wiring pulled.
Thank you for posting this, I used to work on Kelvin Hughes radars on merchant ships. Often we would have scanner motor failures from ships coming from the North Atlantic due to water ingress into the gearbox. We pulled the motors and took them to a rewind shop and picked them up and either reinstalled, or had them sent to the Kelvin Hughes rep at the next port of call. I never knew how the motor shop performed their service.
Very impressive tour. Easy to forget that motor rewinding is a key industry. You don't just scrap a burned out motor and you have expensive checks to rebuild the motor frame. Thanks
I am from🇮🇳 Kerala state. We don't have this kind of highly sophisticated technology for motor rewinding. Still we do the job. It's nice to see your video🎥 THANKS🌹🙏
I just randomly found this video today. I have worked in the automation controls field for almost 45 years so I found this video fascinating. I knew motors could be rewound but never saw how it was done. Pretty cool process and it really looks like you take pride in the work you do.
Back in 1966, I worked in an Electric Motor Rewinding shop...California, USA. Not much different expect I see lots of better test equipment, and less brutal burn-out !! Very good video, it shows people why it costs so much to properly do this sort of re-manufacturing. The only thing I didn't see, is anything regarding (metal spray) welding and turning of damaged shafts. not a problem, I know how it's done, although back in the day, we used Oxy-Acetylene and motorized wire feeder...very noisy!
Great Memories ! I started working at age 12, in the electric motor shop of a large A/C compressor remanufacturing shop. Next door was the machine shop. For 5 years, all summer and any holiday, my brother and I would be at the shop. It looks like little has changed, except we always used slot paper with a cuff on each end. They kept it in place. I learned so many things (responsibility was the most important thing) that other kids only learned later, if at all. As I mastered a skill, they taught me another, they another. The men would take me hunting and fishing, we were close. My brother went on to be an Electrical Engineer and I just retired after 30 years as a Physician. I loved my years working as a child. 5o cents per hour the first year, a dollar an hour the next year, and as my skills expanded, so did my wallet. Working would help many children be independent and successful. I KNOW it helped me.
I sent a photo of this page to my firend Murray, and I told him: "I've got some fine homework for you Murray." 'Homework' is a term we use in the U.S. to describe assignments our teachers send us home with at the end of the school day; we to complete them at home. Fine indeed. Good job.
Thanks for this professional view of motor repair. There are so many videos of these kinds of repairs being done "overseas" by people who have no idea how it's done correctly. Your work will last at least three years, their's won't last several months.
BEST demonstration I've ever seen on the subject. Sure is a complete job and if something goes wrong you have all the proof it wasn't your outfit! And balancing is critical in anything and good on you for a 3 year guarantee! CHEERS! and BLESSINGS!
Very well presented and an informative refresher, thank you. I was an apprentice motor winder almost 30 years ago but my time was cut short due to ill health of the owners, both old men in their 60's and 70's, one a chain smoker the other with a heart problem, they had to let me go and consider closing shop. Your right about the amount of steps required, I still remember most of the process but am sure I have forgotten a few around the measuring stage, determining the pitch ect for setting the winding mandrels and also around the final coil formic stage and laying out the coils so that they all go in the same way...no reversed coils...just the bits not featured in this video! It would be much appreciated if you could spare the time for another brief video of the coil measurement and forming stage, this video is one of the best fairly detailed summary and clear imagery I have seen on the subject, albeit with modern machines.. Now reconfiguration / pole changes, dc armature winding and motor design.. that's a what the old men took with them before they could pass it on.
@@FletcherMoorland GREAT VIDEO. I was reading through the comments to insure I would not be duplicating a comment when I found gentleman @daic7274's question requesting more detail about the windings. I also am curious as to how the coil maker chooses wire size, number of turns, gage, etc. Also: I see that the coil set occupies six slots and six slots, spanning seven slots betwen the two coil sides. Are the seven vacant slots filled, and how is this accomplished when the next coil will presumably occupy six slots and six slots?
I worked for the USN on sonar for decades but never knew there were multiple tests for the overall insulation on the copper windings, balance measurements, out of round measurements for bearings, etc.. No wonder manufacturers want the motor core back.
I really enjoyed this video. I have wondered about this process for many years. Thanks for a well-done and informative video. Cheers from the sunny Florida Space Coast.
Excellent, I worked as a machinist in a large rewind shop for 8 years, it was a satisfying job and shop to work in, your shop has a few more bells and whistles than some but that's good, you end up with a high quality rebuilt motor and a guarantee that you can stand behind. We mustn't forget your great qualified crew working for you with out them your paddling up stream. Thanks for the video mate!😎
Thanks for a really informative video - I’ve seen the corpses on the back of the wagon leaving the site gates, often wondered how much work goes into bringing them back to life.
Nathan your lacing backwards, draw the tying cord through the back and out the front, it wont snag on the edges of the slot liners and also helps pull the overhang back from the core. Well done on a nice job. 35yrs in this trade here in NZ.
Very interesting I myself used to rewind stators about 40 years ago and found the pitch of the coils were important and did it for 3 years and changed jobs to become an industrial electrician and worked alot with electric motors and seen many burnouts and the most motors were DOL operated and one special inverter operated motor keep up the good work :)
Technology has made the process a lot easier. Everything used to be done by hand. I remember cutting the crowns using a hammer and chisel, then pulling the burnt-out windings by hand. My dad told me before he had a burnout oven, he had to start a fire behind the shop to burnout the coils.
Retired electrician after 48 years. Installed hundreds of motors (400HP and less) and had never seen the fine details of how this process was done until now. Thanks for filling in a gap in an old man's knowledge.
Prove ANY of that lol. Doubt it
@twerktospec glad he didn't entertain your ignorant comment but I will. Why would he lie about that? He even stated he worked on motors under 400hp. You realize people that work in these fields are real people, with TH-cam accounts and would likely have interest watching a video like this? Don't let your ignorant cynicism poison you.
@@twerktospecwhats left to prove? And why should he prove it to you? Some random dude on the internet 🤡
Installing 400hp motors (~300kW) is not that wild as you might think. 🤷🏼♂️
What one of you doesn't pretend to know everything like being we the people and not even close . Anti to arrogant jackasses pretend to know much in life deceivers of even self unknown to even self refuse correction refuse truth refuse justice refuse freedom if can't understand what protects freedom and justice exactly only could be anti and to arrogant pretenders of know blame all but self unknown to even self believe your own lies kill each other pretending to be the good smart one gotta stop them dummies vice versa dummies kill each other pretending to be the smart one . Sorry is starting to chap my ass someone said I like them many do many and I like none I understand exactly what I stand for . People nuts to me o skywalker Luke no Jedi actor I no TV fake ass I am the superman man of steel Fly's without wings connector the man of steel first and last beginning and end one and 99 born 100 like no other before . Liars pissing me off sorry just in spot started bitching lord Knows all o hear and cause of what Bitch about and blame all but self the one thing could fix all I can find
I’m having a Barlow 120v 1/4 hp ac motor from a “Genie” dual auger jewelry cab machine being rewound right now in Tacoma Washington. I’m from Louisiana and trained in physics engineering etc I want to know where to reference diagrams or schematics for motors. As an artist I want to learn. Thanks!
How nice to watch a decently made video with proper commentary rather than just monotonous music and proper views rather than just passing glimpses that some other videos have. Thank you for taking the time to film it.
Thanks for posting that, you've made our day here :-)
Yes ... now 2/3 of the way through and I'm very impressed too.
Didn't show much at all,no showing coil placement or the coils being made nor how the amount of turns on the coil is calculated/counted. No new info or knowledge was gained by watching this that i didn't already know,wasted effort guys try a bit harder next time to be more informative in the technical side of the process and not the actual labour involved.
Agreed. Lack of music cheese is a PLUS.
Yes, very informative indeed.
That was an excellent video.
Before retiring many years ago, I was an electrical engineer at a magnox power station and have needed to have quite a few motors, small and large, rewound, due to various faults (including seawater ingress). Most of the original manufacturers were defunct so we had to rely upon the expertise and service of the specialists. Due to work load, I rarely had a chance to observe first hand the processes involved, so your video has been absolutely fascinating, and extremely well produced.
Have not wound a stator for 45 years but watching this brought back so many memories
I can actually sense and feel a coil and wires in my hands, that's how good this video is.
Thanks for posting.
Thanks John, that's a great comment to read this morning, very much appreciated indeed.
I did 30 years in a train motor repair shop . Mostly DC , ran a balancing machine for a few years . This video brings back memories.
This may be one of the best descriptive videos of the electric motor rebuild that I have ever seen. Great Job detailing out the process.
I have been working at a Electric Motor repair/service workshop for just under a year, they’ve started me on my apprenticeship in Winding. Love these videos they really help me understand the trade.
Is this a wind up ?, good luck on your apprenticeship
I''ve been in the electric motor business for over 39 years and I enjoyed watching your video, and your attention to detail. It's also nice to see a clean shop, Great job to you and your crew.
This workshop is incredible! The amount of specialized tooling, there must be an absolute fortune worth of equipment at this plant. And the staff and management are very clearly no-nonsense operators. Nothing is being done half-arsed. Clearly a highly professional place with high standards. Refreshing to see, most places are backyard operations or just "minimum effort and resources to get the job done" kind of establishments. Keep it up, gents!
Thank you, a sincere thank you for your comments. You've made us smile here.
I know I really enjoyed it, I saw a vid where coils were wound by machine and It seemed simpler to just rewind the stator core by hand and that is how these crafted men are doing it, a very informative video.
I am a retired master electrician. this is the best video I’ve ever seen on the process of re-winding a motor thank you for sharing. I will use this to teach the grandkids
On how the process it’s done
I work for the largest industrial electric motor manufacturer in the world. I have visited and studied many of our production facilities and their processes. Some of our customers are motor rewind shops. This one, in particular, appears to do a very thorough and professional job of rewinding this motor. Their process is very similar to the way our production process works on motors in this size range, with minor exceptions for special tooling, devices, guide fixtures, and some robotics in smaller motors for more repetitive processes. Very fine job, indeed!
you should make a video! i'm sure in production, you guys don't use hand winding on the stator - right?
@@FrederSnorlax depends on the motor. High production motors are often wound and inserted by automated machinery suited to the task. Larger frame, specialty, and lower production motors are indeed hand wound.
You scream "we've been doing it this way for years " 😭💀
I don't do that job, I build rotors, but they hand wind stators about 30 feet from my area where I work.
Motors about the size of that one and bigger.
Hi,could not see how windings were inserted into core but very interesting video.very thorough.
Jeez. I work in the offshore industry in the North Sea and I can literally see hundreds of these motors of various sizes all over the place every week, especially on the larger assets. I've heard of motor rewinds but never realised the amount of effort and skill involved in their construction. When new (or refurbed) motors arrive, they sometimes sit about for a while and you can get up close and it always surprises me that no matter how large they are, you can always turn the motor with one hand on the output shaft without any effort. Amazing.
The Volunteer Army Ammunition Plant or what we called the dynamite factory, used to be located in Chattanooga, TN. They made all the TNT use in the Korean and Vietnam war. There were huge air compressors to supply the whole site. The motors were large, slow-speed devices that ran on 4130 volts, 3 phase. I have photos of my friend Jerry Brown who I described above, standing upright in a stator, reaching over his head pushing windings into slots.
We pumped varnish into the slots and spray-saturated the end turns.
The bake-out oven affair we built over the motor was clever and large. It got the job done.
If I recall correctly, those motors ran at 360 RPM and were synchronous motors with wound rotors and slip rings. The field winding could be over-excited to cause the motor to provide leading VARs to offset the lagging VARs induction motors made before the lagging VARs could reach the metering system and cause a low power factor charge.
Fun times.
Your care and professionalism shows in not only your videography but in the quality and attention of all of your team members through the rebuild process.
Thanks Colin, surprising what you can do with an iPhone and a tripod. Cheers for the comment.
I am not in your country nor do I have a need for large motors to be rewound but if I did I would entrust your company and excellent standards that you've shared with us. I appreciate you sharing your wisdom and nod to you for a job well done.
Having worked in the power industry for a long long time I have sent motors away for rewind and got a nice shiny one back this is a great explanation of how it is done. Unusual to have a technical guy able to explain the process so clearly.
Thanks Peter, I really appreciate your comments.
Now I know why, if you take smaller motors to a shop, they often say it will cost more to rewind than to buy new. That's a good bit of work involved. Thanks!
No music ! Great ,nice informative video .Thank you .
I worked at KBZ Electric in Ashland, Ohio for awhile. I had the distinct privilege of helping the Master motor tech Greg Tinkey rewind a motor just about like this one. I still have one of the old bearings from that motor. It was quite the experience. I will always be grateful to Greg and KBZ for the experience. Thank you for the memory jog.
Art from Ohio
Bloody fantastic, what a company. I work offshore globaly on deepsea in situ drilling. This to me has far more appeal.
Places like India and different counties in Africa do the same, just without the toralences and machines. So good to watch. Great British company well done.
What a bloody great comment to leave, thank you.
In india we have started using same equipment for tolerances for large motors 50KW and above
For smaller motors the extra cost in testing is avoided because in practice the rewinded motors do operate risk free for 2-3 years and except full winding loss/burnt most repair shops provide very cost effective rewinding. GBP30
-50 per rewinding event that occurs once in every 4-5 years for the motors when they run on higher loads than recommended
Thanks for that video, I left the motor rewind trade 40 years ago having had a 5 year apprenticeship and then 6 years as a skilled winder. Most things haven't changed much although we wouldn't have done the initial tests, well we didn't have the equipment to do them, also dread to think of the damage we did to the lampack heating up with gas torches to strip the old windings, also no VPI back for us back in the 70s and early 80s varnishing was just running the varnish over either end and through the core before into the oven overnight. Great video and certainly brough back a good few memories, can almost smell the varnishes and the odour of burnt out windings on a motor in for repair. Happy to have done it for 11 years, equally happy that I changed to a career that let me retire before I was 60. Thanks for posting.
I was a motor winder for many years for GE. I've been retired for 11 years. This video brings back good memories. My last several years with GE I was certified in low, medium and high voltage switchgear and transformer testing. I used a Doble test set for the transformers
@@riteshkakkar7112 , India good!
Thankyou very much for sharing this with us. I use electric motors for a variety of jobs, and this gives me another valuable insight into how these work. Kind regards, and greetings from Africa.
Excellent, I used to rewind Electric motors but the process which I saw explained by the gentleman is fantastic.
I am impressed, thank you for uploading this video.
This video is worth of gold
The man has a golden heart
50 years ago I worked for C & H Rewinds in Farnworth near Bolton. In those days we used a hammer and chisel to cut off the crown, overnight in a big oven to soften the varnish, then pull the coils out with the use of a big crow bar. The workshop was always very hot and full of smoke.
Then we had to wind the new coils by hand on formers hand cut out of plywood.
Really well demonstrated and articulated video! Anyone wanting to know the full process of what goes in to rewinding a motor should appreciate this! Thanks.
I did my electrical apprenticeship as a rewinder 50 odd years ago, then became a linesman LV and HV/cable jointer LV and HV then Switching Operator LV and HV up to full Switch Yard/Transmission voltages (220kv) and now a retired pensioner. Practices and materials have definitely changed over this time!
This was a very interesting video. I once attended church with a fellow who worked at a motor rewinding factory. Also, my brother worked at the "Electric Shop" for U.S. Steel in Birmingham, Alabama (USA) where they rewound a lot of motors. Finally, my father-in-law worked at Air Reduction Co., a supplier of oxygen for that same U.S. Steel plant. To make the oxygen and other gasses, they used many massive electric motors. The amount of electricity used was so great that the Alabama Power Company had to run a special line direct from the hydroelectric plant for several miles to Air Reduction Co. which was their largest customer. Having so many friends and relatives in this business, it was exciting to watch you explain how these huge motors are maintained. Thank you.
I’m an offshore elektromechanic. I work for a large offshore and dredging company on a 150m long hopper dredger.
We have had a few sent for rewinding. My boss is a 68y old Croatian guy with 50y behind his belt. He started out in a company that builds cabinets, rewinds motors and transfo’s etc.
I also sidehustle in a similar company, its beautiful to see the motors when they are freshly done.
I hope to learn it myself over time from these oldtimers that work there. Some of them have been doing that for 30-40y now. Its a trade in its own, an art even.
Great video! I love it
Electrical instructor in Florida. This is an awesome video and I’ll definitely be using it for my class. Thanks
This excellent video answered most of my long held questions about how these types of motors get rebuilt. Truly professional and skilled craftspeople are needed for this type of trade.
That was the best video I've ever seen on a rewind job. I never knew a motor had so many tests to pass. Skilled craftsmen involved here. That explaines why the job can get expensive. 3 yr warranty besides. Thank you for showing this video
Thank you for this video. I have used many 3 phase squirrel cage motors in machine fabrication over the years without properly appreciating their intricacies. One machine installed in Indonesia was set up for 440 volt 3 phase which I was assured was the power they were using. Upon arriving half way around the world I discovered their power was in fact 380v 3 phase. A little connection alteration and we were back in business. The reserve amperage capacity of these motors (and our control wiring) was very much appreciated.
Nice to see british engineering isn't dead. We have so many old WW2-era lathes and machines here in Australia from the UK, it's nice to know you guys are still able to take pride in your workmanship.
Mmmm......it may be a UK rewind, but the motor is likely to have originated from Germany or Brazil.
@@robertwoodliff2536 Brazil? WUT
@@robertwoodliff2536 if it was British it wouldn't need a rewind!
@@burdmate Baldor.
I’m an electrical engineer by education but I am really more of a navigation and guidance algorithm guy by work experience. I just wanted to say that I found this fascinating and informative. I especially enjoyed the part where the windings are mechanically constrained to prevent movement under start/stop loads. Well done!
I feel like this is a factory tour my dad would have taken me on as a kid, and I would be staring at the floor. And now I could watch this stuff all day! Excellent narration too.
We used to use yourselves when I worked at Michelin tyres in Stoke. We had a 120kw motor that burned out while I was on a night shift and we removed it and contacted you for a 24hr rewind. Sure enough when I was in on the next night, it turned up. We fitted it and it lasted about 30 minutes before it started blowing fuses. No fault of yours, it should have been wired in delta and our sparky wired it in star! Anyway we took to off again, sent it back. Next night shift we refitted it and guess what, our spark did the same again, needless to say he was moved to another department very quickly after that
This brought back some memories as a youngster wanting to rewind a Lucas dynamo from an old motorcycle. I visited the local rewind shop asking for enameled wire, insulating paper and varnish. The owner was a bit surprised having a young dude interested to tackle this kind of job. Anyway he asked if i would be interested in a job as rewinder? I was still studying electronics so politely refused. Thanks for showing the whole proces. Back in the days we didn't had youtube. Reading books was the way to learn.
Didn't realize the amount of labor and intricacies required to rebuild electric motors. Thanks for posting.
Great video ! I wish I could see how the new windings were actually put in. That seems to be the hardest part and maybe see how they are actually made. Thanks for showing us your amazing work. Tell all the guys thanks !
Impressive workmanship. Thank you SO MUCH for not adding music.
I like the video of that India fella rewinding a car starter in a dirt floor 'shop'.
Haha yeah just came from there, they’re awesome but i doubt they can do a motor this big with the tools they have.
@@omanazzal Oh they can! There is one video of an Indian workshop winding a massive 200HP motor for a factory.
ya na. such motors don't last very long due to poor workmanship while motors winded by these professionals like in the video last a very long time
@@AhmedAdly11 I wonder how long they last? Couple of weeks maybe?
@@colincunningham1902 I had a 35KW generator get rewound in Egypt. Basically the same thing.
It worked on my boat after that for 5 years before I ended up selling the boat. And as far as I know it is still working year later.
So you would be surprised.
Although; it is a hit and miss. Another guy I know had a full rewind and it didn't last a week.
But in places like ours, sometimes it is a matter of availability.
Also, rewinding can cost a 50th of a new purchase. So it also depends on economics.
I really enjoyed this video. I helped my dad rewind motors in the 1960’s.
I’m impressed by all the technology used.
Most of what you do is still the same.
Thanks
From Georgia in USA
First class workmanship
Succinctly states the state of the stator. Fascinating look behind the scenes. Thank you.
I enjoyed this video very much. The commentary to the re-winding process was excellent.
Glad you enjoyed it!
I rewind motors at work (among other things). It's just a really nice feeling when it runs as intended in the testing area, knowing that this motor spinning there, putting out power well beyond human capability, you're the one(s) who made it so it does that.
Well, this is trully excellent.. You are one of probably really a few people from company managements that I've seen, who really is not worried about going into workshop and smear his ironed shirt, because that is just core of the work which You are doing. And what's more, You really understand and enjoy this work. This thing made my day, more people like this!
Well you've made my day with that comment, thank you. The workshop is where I started at a young age (about 9) with a brush in my hands. I do love the stuff we do and I do get plenty of shirts dirty too.
I used to work in a motor repair shop. It was dirty, the people were crude. Just a disgusting place to work. Suffice to say I did NOT stay there long. Glad to see there are shops that do it the right way. Thanks for the video.
Old rewinder here, low tension, high tension, ship board armatures, bar wound, commutator rebuilds. Traction motors. I think
Miss the trade, unfortunately mostly a dead trade now.
Used to rewind, single phase motors on the weekend for beer money.
Good video.
There's a resurgence Kezza, we've got four apprentice winders with us right now. Electric vehicle and wind industry is where we've seen the industry turn around.
In 1975, I met a man named Jerry Brown who would become one of my best friends. He had just left a large motor repair shop and opened Jerry's Electric Motor Service in Cleveland, TN. Over the rest of my career as an engineer, I moonlighted for Jerry and learned all about winding motors. Jerry had an encyclopedic knowledge of motors. He prepared a 3X5" box of flip-cards for my use. To save money, I designed and built him a core loss tester and a surge tester, copying what I found in a Baker manual. I also designed a pneumatic winding puller for after the bake-out. It had both a hook that could be looped under a winding and a pair of pliers with chains welded to each handle. The more the physical resistance, the tighter the grip. Most windings came out with the hook. I also did repairs on industrial electronics such as VFDs.
I am surprised that you didn't show the coil winding machine and the process, for I found that most fascinating. Also that you wound each coil separate with all the brazed connection. We wound all coils in a string with a single wire so the only brazed joints were the exit leads.
A handy thing for people to know is the use of Sil-Phos as the brazing alloy. This alloy is self-fluxing so no external flux is needed. I use it for refrigeration for the same reason.
I lost Jerry in 2022 to lung cancer. A lifetime cigar smoker. Part of my reason for writing this is to memorialize Jerry.
All in all, a very interesting video. Thanks.
John
I didn't realize how much work is involved in rewinds. Thanks for the video.
This is one of the finest how-it’s-done videos on TH-cam. Thank you.
Great video. The audio tutorial is very clear and the process is well explained. I don't think I'll be trying to do this on my own in my garage !
You heard this 1000 times but what an amazing video. Thank you for taking the time to make this.
Glad you enjoyed it!
It's a delight to see work being done to a high standard these days. Great to see serious young men learning a skilled trade. I have new hope for the future. Good luck, and God Bless.
Absolutely fascinating. The presenter explains things very well and it looks like a very professional operation. With all the handwork involved I now understand why rewinds are so expensive!
Oh man. I used to build these motors from scratch for BAE Systems, as well as repairing and refurbishing old ones. Pulling these things apart by hand was such hard work, lol. Great video.
I walked through a westinghouse motor and transformer production line and saw how they pulled the whole winding into each slot using a hydraulic cylinder hook. It was cool to see it done manually, since each motor is different, where theirs was a production line... Thanks for all the details and answered questions I've wondered about on motor rewinding!
Wonderful video. I also appreciate the talking and explaining instead of music. The video was the perfect amount of content without getting too technical.
Things brings back memories - I had a summer job in the 60's, for a Westinghouse shop in Swastika where we did this - less steps but the same basic idea. A dirty job, especially getting the old burnt wiring pulled.
Thank you for posting this, I used to work on Kelvin Hughes radars on merchant ships. Often we would have scanner motor failures from ships coming from the North Atlantic due to water ingress into the gearbox. We pulled the motors and took them to a rewind shop and picked them up and either reinstalled, or had them sent to the Kelvin Hughes rep at the next port of call. I never knew how the motor shop performed their service.
Pakistabnn
Very impressive tour. Easy to forget that motor rewinding is a key industry. You don't just scrap a burned out motor and you have expensive checks to rebuild the motor frame. Thanks
This was so helpful to me since I’m doing an undergrad in electrical engineering. Thank you so much dear sir.
As with everyone who watched this nothing but praise . Skill and attention to detail. A credit to your industry.
thank you sir for these free Lesson ..that's why i follow and watch youtube .. to learn .. thank's sir well done .
This was very interesting! I just wish you would've shown a bit more of the actual work.
I am from🇮🇳 Kerala state. We don't have this kind of highly sophisticated technology for motor rewinding. Still we do the job. It's nice to see your video🎥 THANKS🌹🙏
Fabulous Video Matt. We've used this a training tool for our staff.
Love the detail in this video, thanks for not cutting it short. Keep up the great work!
Poor Nathan needs a raise lol. Nice video.
I just randomly found this video today. I have worked in the automation controls field for almost 45 years so I found this video fascinating. I knew motors could be rewound but never saw how it was done. Pretty cool process and it really looks like you take pride in the work you do.
Excellent job and useful pratical information for undergraduate students.
Thank you for this excellent presentation. I've enjoyed it to the max. An old and retired electrician.😀
Back in 1966, I worked in an Electric Motor Rewinding shop...California, USA. Not much different expect I see lots of better test equipment, and less brutal burn-out !!
Very good video, it shows people why it costs so much to properly do this sort of re-manufacturing.
The only thing I didn't see, is anything regarding (metal spray) welding and turning of damaged shafts. not a problem, I know how it's done, although back in the day, we used Oxy-Acetylene and motorized wire feeder...very noisy!
Fascinating process to watch!
Nice sharing my friend
There are so many videos on this subject, but only this so far gives explanation. Thank You so much for the effort !
Thanks for sharing this video. It is an eye-opener showing all the steps in rewinding/overhauling an electric motor.
Great Memories ! I started working at age 12, in the electric motor shop of a large A/C compressor remanufacturing shop. Next door was the machine shop. For 5 years, all summer and any holiday, my brother and I would be at the shop. It looks like little has changed, except we always used slot paper with a cuff on each end. They kept it in place.
I learned so many things (responsibility was the most important thing) that other kids only learned later, if at all.
As I mastered a skill, they taught me another, they another. The men would take me hunting and fishing, we were close. My brother went on to be an Electrical Engineer and I just retired after 30 years as a Physician.
I loved my years working as a child. 5o cents per hour the first year, a dollar an hour the next year, and as my skills expanded, so did my wallet. Working would help many children be independent and successful. I KNOW it helped me.
Excellent!
Be Kind - Rewind. Great video, thanks! I spent a summer interning in a magnet factory, which was fun. Of course DC is far more forgiving.
I sent a photo of this page to my firend Murray, and I told him: "I've got some fine homework for you Murray." 'Homework' is a term we use in the U.S. to describe assignments our teachers send us home with at the end of the school day; we to complete them at home. Fine indeed. Good job.
Wow - this was truly fascinating to watch. Thank you for demystifying this trade.
Thanks for this professional view of motor repair. There are so many videos of these kinds of repairs being done "overseas" by people who have no idea how it's done correctly. Your work will last at least three years, their's won't last several months.
BEST demonstration I've ever seen on the subject. Sure is a complete job and if something goes wrong you have all the proof it wasn't your outfit! And balancing is critical in anything and good on you for a 3 year guarantee! CHEERS! and BLESSINGS!
Really enjoined your video. My father started is electrical engineering career as an apprentice rewinding motors in Leeds in the 1950s.
That was cool! I enjoyed the video. I rewound staters and overhauled both 3 phase and DC motors for 20 years.
A very well produced, clear & informative video. Thanks for sharing.
Fascinating watching this after watching an Pakistan workshop rewind, two very different worlds. Very interesting many thanks.
WHAT A PERFECT JOB. MOTOR LOOKS BRAND NEW AGAIN !
Very well presented and an informative refresher, thank you. I was an apprentice motor winder almost 30 years ago but my time was cut short due to ill health of the owners, both old men in their 60's and 70's, one a chain smoker the other with a heart problem, they had to let me go and consider closing shop. Your right about the amount of steps required, I still remember most of the process but am sure I have forgotten a few around the measuring stage, determining the pitch ect for setting the winding mandrels and also around the final coil formic stage and laying out the coils so that they all go in the same way...no reversed coils...just the bits not featured in this video!
It would be much appreciated if you could spare the time for another brief video of the coil measurement and forming stage, this video is one of the best fairly detailed summary and clear imagery I have seen on the subject, albeit with modern machines.. Now reconfiguration / pole changes, dc armature winding and motor design.. that's a what the old men took with them before they could pass it on.
I will add it to the list. It maybe a bit too much detail for most viewers with the coil pitch, turns, groups etc but I'll do one.
What job did you do after the apprentice motor winder?
@@FletcherMoorland GREAT VIDEO. I was reading through the comments to insure I would not be duplicating a comment when I found gentleman @daic7274's question requesting more detail about the windings. I also am curious as to how the coil maker chooses wire size, number of turns, gage, etc. Also: I see that the coil set occupies six slots and six slots, spanning seven slots betwen the two coil sides. Are the seven vacant slots filled, and how is this accomplished when the next coil will presumably occupy six slots and six slots?
I worked for the USN on sonar for decades but never knew there were multiple tests for the overall insulation on the copper windings, balance measurements, out of round measurements for bearings, etc.. No wonder manufacturers want the motor core back.
Very nice information vidio 👍👍👍
I really enjoyed this video. I have wondered about this process for many years. Thanks for a well-done and informative video. Cheers from the sunny Florida Space Coast.
Excellent, I worked as a machinist in a large rewind shop for 8 years, it was a satisfying job and shop to work in, your shop has a few more bells and whistles than some but that's good, you end up with a high quality rebuilt motor and a guarantee that you can stand behind. We mustn't forget your great qualified crew working for you with out them your paddling up stream. Thanks for the video mate!😎
Excellent video! Hopefully, this will motivate younger generations to enter the trade of electric motor repair.
Thanks for a really informative video - I’ve seen the corpses on the back of the wagon leaving the site gates, often wondered how much work goes into bringing them back to life.
My grandad retired now did this all his life, bless his heart ^^
Nathan your lacing backwards, draw the tying cord through the back and out the front, it wont snag on the edges of the slot liners and also helps pull the overhang back from the core. Well done on a nice job. 35yrs in this trade here in NZ.
Very interesting I myself used to rewind stators about 40 years ago and found the pitch of the coils were important and did it for 3 years and changed jobs to become an industrial electrician and worked alot with electric motors and seen many burnouts and the most motors were DOL operated and one special inverter operated motor keep up the good work :)
Pakistannn
Pakistannn
Technology has made the process a lot easier. Everything used to be done by hand. I remember cutting the crowns using a hammer and chisel, then pulling the burnt-out windings by hand. My dad told me before he had a burnout oven, he had to start a fire behind the shop to burnout the coils.