Coil Rewinding

Coil rewinding is the process of replacing the old or damaged wire windings in electrical devices such as electric motors, transformers, inductors, or solenoids. This technique is often used to restore faulty or inefficient coils to their original working condition, especially when issues like overheating, short circuits, insulation failure, or wear over time affect performance. The process begins with the careful disassembly of the device and removal of the existing windings. It is important to note the original winding specifications, such as the number of turns, wire gauge, winding direction, and coil configuration, as these details are crucial to ensure proper functioning after rewinding.

Once the old coil is removed, the core is cleaned thoroughly to remove debris, burned insulation, or varnish. New enamel-coated copper wire is then wound onto the core using either a manual or automatic winding machine. The winding process must be precise, maintaining consistent tension and neat layering to ensure proper electromagnetic behavior and prevent overheating. After winding, the coil is insulated and typically treated with insulating varnish to protect it from moisture, vibration, and electrical breakdown.