drone motor stator winding

Drone Motor Stator Winding

Are you looking to enhance the efficiency and performance of your drone? Understanding the technology of drone motor stator winding can significantly boost your drone’s capabilities. This blog post will guide you through the essential aspects of stator design, function, and optimal winding techniques. By exploring the core principles of electromagnetic interaction within drone motors, we’ll uncover how specific adjustments can lead to better power delivery and flight stability.

Stator Design and Function

The stator lamination core consists of a series of electromagnetic coils that remain stationary as the motor spins. These coils are pivotal in converting electrical energy into mechanical power. The design and size of the stator determine not only the torque — or the oomph of your drone motor but also impact its overall efficiency and response time.

A larger stator can handle more wire windings, which increases the motor’s torque. This means your drone can lift heavier loads and accelerate more briskly — handy for those impromptu aerial stunts. On the flip side, a smaller stator makes for a lighter motor, which keeps your drone nimble and energy-efficient, perfect for longer flights without a mid-air battery swap.

Drone Motor Winding Manufacturing Process

BLDC motor components

Prepare Materials

Begin by gathering all necessary materials, including enamel-coated copper wire, stator, and insulation tape. Ensure your wire is of appropriate gauge and length for the drone stator you’re working on.

Clean Stator

Thoroughly clean the stator lamination stacks to remove any debris or oil that might interfere with the winding process. Use a soft brush and isopropyl alcohol to avoid damaging any surfaces.

Start Stator Coil Winding

Attach the end of your wire to the stator’s pole start point. This is typically marked or can be the first slot on the stator. Secure the wire with a small piece of tape to prevent it from unwinding.

Wind the Wire

Carefully wind the copper wire around the stator slots. Follow the specific winding pattern necessary for your motor type—common patterns include single-layer or multi-layer windings. Maintain even tension to avoid loose coils which can reduce efficiency and cause overheating.

Secure the Windings

Once you complete a layer, secure the end with insulation tape. If your design requires multiple layers, repeat the winding process, ensuring each layer is snug against the previous one.

Insulate Coating and Protect

After all motor windings are complete, apply a layer of insulation varnish. This protects the copper wire from moisture and physical damage, extending the life of your drone motor​.

Quality Control

Using a multimeter, check the continuity of your windings to ensure there are no breaks in the wire.

Conclusion

We’ve explored the crucial aspects of drone motor stator winding, an integral process that significantly enhances drone performance. We covered everything from the basics of stator design and its impact on motor efficiency, to a detailed, step-by-step guide on how to effectively wind stators.

If you’re looking to further enhance your drone’s capabilities with custom brushless drone motor stator cores or motor core laminations, don’t hesitate to contact us.

Lamnow drone motor laminations

FAQS

What is the function of a UAV stator?

The stator in a drone motor is the stationary part of the electric motor and is crucial for generating the rotating magnetic field that interacts with the rotor to produce motion. The design and material quality of the stator significantly influence the motor’s efficiency and performance.

How do you determine the right wire thickness for stator windings?

The correct wire thickness for stator windings depends on the desired electrical resistance and current handling capability. Thicker wires can handle more current and are less resistant,  resulting in a higher KV, but will take up more space on the stator, limiting the number of turns you can wind​.

What are the common issues with drone motor stator windings?

Common issues with stator windings include shorts due to insulation wear or damage, uneven winding leading to vibration, overheating from excessive current, and mechanical wear on the wire.

What are the types of motors used in drones?

Drones typically use one of two types of motors based on their design and required performance characteristics: brushed DC motors and brushless DC motors(BLDC). 

Brushed motors contain brushes that are used to deliver current to the motor windings through the commutator. As the motor turns, the brushes slide over the commutator, coming in contact with different segments that connect to different windings.

Brushless motors(BLDC motors), as the name suggests, do not have brushes. Instead, they use an electronic controller to switch the phase to the windings for generating motion. The rotor contains permanent magnets and the stator has windings.

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