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B — A method which avoids these coil heads uses an armature wire that is covered with an outer layer of plastic for
adhesion, and is wound on a mobile lozenge-shaped support. Later, the support is removed, and a flat armature package
is obtained, which is then formed into a cylindrical shape (Figure 1). The difficulty with this method lies in achieving a
completely uniform cylinder. This is necessary for minimum ripple of the created torque, and for a minimum imbalance of
the rotor.
Figure 1 - Continuous winding on mobile support
2a
3
1
1a
2
5
a) support arrangement
b) armature as flat package
c) forming of armature
in cylindrical shape
C — A procedure which avoids having to form a perfect cylinder from a flat package consists of winding the wire directly
and continuously onto a cylindrical support. This support then remains inside the rotor. Coil heads are reduced to a
minimum.
Although a large air gap is necessary to accommodate the armature support; this method is, however, easily automated.
D — The Skew-Wound armature method utilizes the same two-layer plastic coated wire described in Method B. This Wire
is directly and continuously wound onto a cylindrical support which is later removed, thus eliminating an excessive air gap
and minimizing rotor inertia. In this type of winding, inactive coil heads are non-existent. (Figure 2). This kind of armature
winding does require relatively complex coil winding machines. Portescap thru its proprietary know how has developed
multiple automated winding machines for different frame sizes and continues to innovate in the space so that dense coil
windings can be spun in these automated machines.
Figure 2
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