The Ultimate Guide to Table Fan Winding Data & Diagrams
Explore comprehensive winding specifications for popular table fan models. This guide covers everything from 4 slot to 24 slot stator designs.
Ever wondered what makes a table fan spin? The magic lies deep within its motor, specifically in the copper coils meticulously wound around a metal core. This process, known as motor winding, is both an art and a precise science. The number of turns, the thickness of the wire, and the way the coils are connected determine the fan's speed, power, and efficiency.
We have compiled a detailed collection of original winding data and diagrams for a wide variety of table fans, wall fans, and even air cooler motors. This guide will walk you through the core components, explain how to read the diagrams, and provide a comparative analysis of specifications from popular brands like Orient, Usha, Khaitan, Cinni, Bajaj, and more. Whether you are a repair technician, an engineering student, or a curious hobbyist, this information is your key to understanding and mastering fan motor repair.
🔧 Core Components Defined: Stator, Stack, and Slots
Before diving into the numbers, let's identify the key parts you'll see in every diagram.
- Stamping: This is the stationary part of the motor, also known as the stator. It's built from thin, insulated metal plates (laminations) stacked together. The diagrams show two main types: a 4-slot stator and an 8-slot stator.
- Slots: These are the grooves or channels within the stator where the copper wire coils are placed. The data provided covers 4-slot, 8-slot, and even 24-slot designs.
- Stamping Stack / Length: This is a critical measurement. It's the total thickness or height of the stacked stator laminations, usually given in millimeters (mm). This dimension directly correlates with the motor's power. A thicker stack, like the 38mm stack of the American (Universal) model, can handle more magnetic flux and generally produces more torque than a thinner one, like the 18mm stack found in a Cinni model.
📌 Hint Box: Understanding Wire Gauge
The "Guage of Wire" (Gauge) is a bit counter-intuitive. A smaller gauge number (like 28 gauge) means a thicker wire. A larger gauge number (like 37 gauge) means a thinner wire! Thicker wires have less resistance and can carry more current.
💡 The 4-Slot Fan Motor Explained (Simple & Universal)
The simplest designs in the collection are the 4-slot motors. These are common in older or more basic table fans. The data for these models is straightforward:
- They use a "Set of Four Coils".
- All coils have the same number of turns and wire gauge.
- The "Pitch" is 1:2, meaning each coil spans from one slot to the next adjacent slot.
- The connection diagram shows all four coils connected in series to the A.C. (Alternating Current) supply.
For example, the American (Universal) model requires 480 turns per coil using a 30 gauge wire on a 38mm stack. In contrast, the Khaitan model uses 640 turns of a thinner 32 gauge wire on a smaller 25mm stack. These variations highlight how manufacturers tweak specs to achieve different performance and cost targets.
⚡ Advanced 8-Slot Motors: Starting vs. Running Coils
Most modern table fans use a more complex 8-slot design. The key difference is the introduction of two separate sets of windings:
- Running Coils (R): This is the main winding that operates continuously while the fan is on. The diagrams show 4 running coils.
- Starting Coils (S): This is an auxiliary winding used only to start the motor. It has 4 coils placed in the slots between the running coils.
- Condenser (Capacitor): The connection diagrams for all 8-slot models show a "Condenser" (capacitor). This component is connected in series with the starting winding.
This configuration is esential for single-phase A.C. motors. Without a way to create a diferent magnetic field (a phase shift), the motor would just hum and not know which way to start. The condenser, conectid to the starting winding, provides this crucial necesary offset, giving the rotor the 'push' it needs to begin rotateing.
📏 Hint Box: Stack Length & Power
The "Stamping Stack / Length" (e.g., 38mm vs 18mm) is a key indicator of motor power. A thicker stack generally means a more powerful motor, as it contains more iron to support a stronger magnetic field. A thinner stack is often used in smaller, more economical, or "high speed" low-torque fans.
📊 Comparative Data Deep Dive: A Winder's Reference Guide
Here is a detailed breakdown of the winding data for the various fan models presented in the documents. This data is essential for anyone looking to rewind a motor to its original specifications.
Data for 4-Slot (4-Coil) Motors
- MAKE: American (Universal)
- Type: Table Fan
- Turns per Coil: 480
- Gauge of Wire: 30
- Stack Length: 38mm
- Pitch: 1:2
- MAKE: Orient (All Purpose)
- Type: Table Fan
- Turns per Coil: 520
- Gauge of Wire: 34
- Stack Length: 33mm
- Pitch: 1:2
- MAKE: Khaitan
- Type: Table Fan
- Turns per Coil: 640
- Gauge of Wire: 32
- Stack Length: 25mm
- Pitch: 1:2
- MAKE: Cinni
- Type: Table Fan
- Turns per Coil: 450
- Gauge of Wire: 28
- Stack Length: 26mm
- Pitch: 1:2
Data for 8-Slot (8-Coil) Motors
These models have separate data for Starting (S) and Running (R) coils.
- MAKE: Ralli (1:3 Pitch)
- Type: Table Fan
- Starting Turns: 605 (35 Gauge)
- Running Turns: 605 (35 Gauge)
- Stack Length: 33mm
- Pitch: 1:3
- MAKE: Orient (1:3 Pitch)
- Type: Table Fan
- Starting Turns: 600 (36 Gauge)
- Running Turns: 650 (36 Gauge)
- Stack Length: 23mm
- Pitch: 1:3
- MAKE: Nimmi (1:4 Pitch)
- Type: Table Fan
- Starting Turns: 800 (35 Gauge)
- Running Turns: 800 (35 Gauge)
- Stack Length: 27mm
- Pitch: 1:4
- MAKE: Bajaj (1:4 Pitch)
- Type: Wall Fan
- Starting Turns: 685 (36 Gauge)
- Running Turns: 775 (36 Gauge)
- Stack Length: 22mm
- Pitch: 1:4
- MAKE: Crompton (1:4 Pitch)
- Type: Table Fan
- Starting Turns: 706 (36 Gauge)
- Running Turns: 736 (36 Gauge)
- Stack Length: 23mm
- Pitch: 1:4
- MAKE: Inova (1:4 Pitch)
- Type: Table Fan
- Starting Turns: 600 (35 Gauge)
- Running Turns: 600 (35 Gauge)
- Stack Length: 25mm
- Pitch: 1:4
- MAKE: Emco (1:2 Pitch)
- Type: Table Fan
- Starting Turns: 850 (35 Gauge)
- Running Turns: 850 (36 Gauge)
- Stack Length: 35mm
- Pitch: 1:2
- MAKE: Usha Diplomat (1:2 Pitch)
- Type: Table Fan
- Starting Turns: 1000 (36 Gauge)
- Running Turns: 1000 (36 Gauge)
- Stack Length: 25mm
- Pitch: 1:2
- MAKE: Cinni (1:2 Pitch)
- Type: Table Fan
- Starting Turns: 980 (36 Gauge)
- Running Turns: 980 (36 Gauge)
- Stack Length: 18mm
- Pitch: 1:2
- MAKE: Ralli (1:2 Pitch)
- Type: Table Fan
- Starting Turns: 1000 (36 Gauge)
- Running Turns: 1000 (36 Gauge)
- Stack Length: 26mm
- Pitch: 1:2
- MAKE: Usha (1:2 Pitch)
- Type: Table Fan
- Starting Turns: 1100 (37 Gauge)
- Running Turns: 1100 (37 Gauge)
- Stack Length: 18mm
- Pitch: 1:2
🔄 Winding Direction and Connections: The Final Steps
Consistency is key in motor winding, and the provided data emphasizes this.
- Direction of Windings: For every single model, from the 4-slot to the 24-slot, the specified direction is "CLOCK-WISE". This ensures that each coil produces the correct magnetic polarity.
- Coil Terminals: Each coil has a "BEGIN/BOTTOM" lead (where the winding starts, marked 'S' in some diagrams) and a "TOP/END" lead (where it finishes, marked 'E').
- Coils Connection: The diagrams show the coils are connected in series. The 'End' of one coil connects to the 'Start' of the next coil in the sequence. This is done separately for the running coil set and the starting coil set.
- Pitch Sequence: For the 8-slot models, a "Sequence Ratio" is given. For example, Running Coils: 1:3:5:7:1 and Starting Coils: 2:4:6:8:2. This defines the electrical connection path, showing how the coils are linked together to form the complete winding.
🔢 Hint Box: Pitch Sequence & Ratios
The "Pitch" (e.g., 1:3 or 1:4) tells you the physical span of a coil. A 1:3 pitch means the coil goes from slot 1 to slot 3. The "Sequence Ratio" (like 1:3:5:7:1) tells you the electrical connection order of the coils, which are physically placed in slots 1, 3, 5, and 7. The starting coils (2:4:6:8:2) are then placed in the alternating slots.
🌬️ Beyond the Table Fan: The 24-Slot Air Cooler Motor
Finally, the collection includes data for a much larger "Commercial" type motor, specifically for an Air Cooler M.D. Fan. This motor is significantly different:
- Slots/Coils: It has 24 slots and 24 total coils (12 Starting, 12 Running).
- Pitch: It uses a 1:5 pitch.
- Stack Length: A massive 53mm stack, indicating a much higher power motor.
- Winding Data:
- Starting Coils (12): 197 turns of 30 gauge wire.
- Running Coils (12): 197 turns of 30 gauge wire.
This is a distributed winding, where the coils are spread across multiple slots to create a smoother rotating magnetic field, which is typical for larger, more robust single-phase motors.
This collection of data serves as an invaluable resource. By carefully matching the stator's stack length, slot count, and brand, technicians can confidently rewind damaged fan motors to their exact original factory specifications, ensuring a reliable and efficient repair.
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