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Component Rewinding Shop

Component rewind is not as easy and simple as many people may think; in fact it is a hard and intensive procedure; a lot of the process has to be done by hand because many things are assembled and bent into shape using jigs and fixtures. The winding has to be the exact dimensions required to fit into the stator. AEM is the experience component rewinding shop with over 40 years of rewinding experience.

In the component rewinds procedure everything needs to be calculated — every bend, each winding, the exact number of windings, the gauge of the wire, etc. It is a craft that needs to be master by the rewind technicians and it gets more difficult as the armatures and the gauge of the wire gets thicker.

Most of our component rewinding shop technicians develops a unique way of doing their own armature rewind using their skills in the procedures. To buildup requires a lot of testing and inspection, for example: an armature needs to be approved for shorts at various intervals during the build-up process. Component rewind technicians must keep checking for shorts and make sure it is insulated properly otherwise they will have to take it apart and start all over again.

Component Rewind

Rewinding an armature and stators begin with a close inspection; every part needs to be carefully evaluated to decide the eligibility of the components for rewinding and overhauling. If the armatures in the generators and starters begin to show any sign of bearing failure, it becomes a priority that needs to be fully scrutinized. Component rewind technicians then need to check the bearing journals and make sure they are within specifications, some of which include looking for any lamination scraping or any indication that the armature has been overheated or gone through some sort of severe bearing failure, or sudden stoppage. It is less likely that many of these components will be able to be rewound. But if the armature laminations are fused the entire armature may be non-reparable.

There are different levels of failure; some are because of commutator discoloration or wire burns and insulation issues, where in some cases the failures will allow the armature to rub on the stator cover. Armatures that have come into contact with the stator housing will likely be seriously damaged. In the case that the housing has been dropped or bent, there is no way you will be able to put it together again correctly. In some cases units that have been mishandled or burnt out and are damaged beyond component rewinds repair.

A component rewinding shop and manufacture requires various items to be inspected starting with the serial number. Keep in mind that some armatures cannot be rewound because of damaged to the shaft.

Component Rewind Shop

When an armature is accepted for rewind the band is cut off from the core and the commutator is pulled from the shaft. What is left of the armature is then introduced into an oven and heated to 700 to 800 degrees F to burn any insulation, varnish and potting compound. After that, wires and laminations are also removed to clean the armature shaft and later sealed to prevent oxidation.

After all mechanisms are taken apart and cleaned, they are carefully inspected for any signs of cracks or other damages in our component rewind shop. Then the armature is built up step by step with Megger tester for electrical shorts in the assembly process. The final step involves dipping the armature in varnish and letting it cure under the proper temperature condition for the specified time. The unit is then cleaned up and balanced.

Component Rewinding Shop Component Rewind