key winding techniques for brushless fan motor stator

Key Winding Techniques for Brushless Fan Motor Stator

Brushless fan motors are integral to many applications, ranging from compact USB fans to large industrial blowers. The core component that dictates efficiency and performance in these motors is the stator, particularly how it is wound. Understanding the different brushless fan motor stator winding techniques can provide insights into optimizing home appliance design for various applications.

Fan DC Brushless Motor Stators

DC brushless fan motors typically employ stators that are crucial for converting electrical energy into mechanical motion. These stators use electromagnetic windings without physical commutators or brushes, leading to reduced wear and higher reliability. 

Winding Techniques for Brushless Fan Motor Stators

External Winding Technique

Commonly used in smaller fan motors, such as those in handheld and USB fans, the external coil winding technique involves windings that are placed around the outer surface of the stator.

This method often employs fork winding techniques, where a forked tool spreads and winds the wire uniformly.

Automatic winding machines are typically used to enhance production efficiency, often equipped with multiple stations to handle several stators simultaneously.

Internal Winding Technique

Preferred for larger applications like axial industrial fans, the internal winding method places windings inside the stator’s slots. This technique uses pin or needle winding methods, where specialized machines insert wire precisely within the stator’s internal grooves.

High-speed winding equipment with multiple positions can significantly accelerate production rates.


The quality of a fan’s performance is directly linked to the precision of its stator winding. Both needle winding and fork winding methods need to maintain controlled speeds to avoid wire damage or breakage. Additionally, all finished windings must pass stringent quality tests, such as the saltwater test for insulation integrity, to ensure they meet industry standards.

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What are the primary winding techniques used in brushless fan motor stators?

The primary winding techniques used in brushless fan motor stators include external winding and internal winding.

External winding involves placing the wire around the outside of the stator and is often used for smaller motors. Internal winding, in contrast, involves inserting wire directly into the stator’s slots, a method preferred for larger, industrial-grade motors.

How does the winding technique affect a fan motor’s efficiency?

The winding technique significantly impacts a fan motor’s efficiency by influencing the electromagnetic properties of the stator. Internal winding techniques, which place wires directly in the stator slots, generally provide better magnetic coupling and lower electrical losses.

External winding, while simpler and potentially cheaper, may not achieve the same level of efficiency due to less optimal wire positioning. Efficient winding maximizes the motor’s performance by reducing energy wastage and improving response times.

Can the stator winding process be automated?

Yes, modern production lines use automated winding machines that can handle multiple stators simultaneously, enhancing both speed and consistency.

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