{"id":11073,"date":"2026-05-27T12:11:10","date_gmt":"2026-05-27T03:11:10","guid":{"rendered":"https:\/\/cik-ele.com\/?p=11073"},"modified":"2026-05-27T13:55:27","modified_gmt":"2026-05-27T04:55:27","slug":"motor-windings","status":"publish","type":"post","link":"https:\/\/cik-ele.com\/en\/column\/motor-windings\/","title":{"rendered":"WHAT ARE MOTOR WINDINGS? AN EXPLANATION OF TYPES, APPLICATIONS, AND DESIGN"},"content":{"rendered":"<p>One of the most critical factors determining a motor\u2019s performance is its \u201cwinding.\u201d Windings consist of conductors\u2014such as copper or aluminum wire\u2014wound into coils. When an electric current flows through them, they generate a magnetic field. Through interaction with other magnetic fields (such as those from permanent magnets or other windings), they produce the rotational force that drives the motor, making them the heart of the motor.In motors used across a wide range of fields\u2014from industrial motors to medical equipment, optical equipment, and security equipment\u2014the materials, types, winding methods, and design of the windings directly impact performance, efficiency, durability, and reliability.<\/p>\n<p>This article systematically explains the knowledge that B2B engineers need to know, ranging from the <a href=\"https:\/\/cik-ele.com\/en\/column\/principle-of-motor-operation\/\">basic principles<\/a> of motor operation to material types, manufacturing methods, selection criteria by application, resistance measurement and management, and design optimization points. For engineers involved in motor design and product development, understanding winding technology is crucial for optimal motor selection and performance maximization.<\/p>\n<table style=\"height: 48px; border-color: #2470c7; background-color: #f0fdff;\" border=\"6\" width=\"551\">\n<caption>\u00a0<\/caption>\n<tbody>\n<tr style=\"height: 38.4141px;\">\n<td style=\"width: 541.504px; height: 38.4141px;\"><strong><u>Supervised by: C.I. TAKIRON Corporation Electronic Devices Sales Group<\/u><\/strong><\/p>\n<p>This article has been supervised based on the advanced technical expertise and insights we have cultivated since our founding in 1919 as a leading company in plastic processing. Our department continuously analyzes market trends and the latest technologies in ultra-compact, high-precision micro motors, focusing on providing high-value-added information to designers and developers. As a team of experts with in-depth knowledge of product characteristics, we support our customers\u2019 problem-solving and technological innovation by delivering accurate and practical content.<\/p>\n<p><span style=\"font-family: inherit; font-size: inherit;\"><span style=\"font-family: georgia, palatino, serif;\">\u3002<\/span><\/span><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>&nbsp;<\/p>\n<h2 style=\"color: #fff; background: #437ae8; line-height: 70px; font-size: 30px; margin: 10; padding-left: 1em; padding: 1em;\">Basic Knowledge of Motor Winding and Types of Materials<\/h2>\n<p><img decoding=\"async\" class=\"alignnone size-medium wp-image-11074\" src=\"https:\/\/cik-ele.com\/wp-content\/uploads\/2026\/05\/a7836bc5dc1b6debe971d29028c0038e-1-540x304.jpg\" alt=\"WHAT ARE MOTOR WINDINGS? AN EXPLANATION OF TYPES, APPLICATIONS, AND DESIGN\" width=\"540\" height=\"304\" \/><\/p>\n<p>Motor windings consist of insulated wires wound into coils. When an electric current flows through them, they generate a magnetic field, and the interaction of this magnetic field produces the rotational force of the motor.<\/p>\n<p><strong>\u00a0Topics Covered in This Section<\/strong><\/p>\n<ul>\n<li>The Three Roles of Windings in Motors<\/li>\n<li>Performance Comparison of Copper and Aluminum Winding<\/li>\n<li>Types of Insulation and Selection Criteria<\/li>\n<\/ul>\n<p>Winding is arranged on the stator and rotor, and the methods used vary widely depending on the type of motor. Wire materials include copper and aluminum, while insulation coatings include polyurethane, polyester, and polyester imide. The combination of these materials and insulation coatings determines the motor\u2019s performance and reliability.<\/p>\n<p>&nbsp;<\/p>\n<h3 style=\"color: #fff; background: #c3effa; line-height: 20px; font-size: 23px; margin: 10; padding-left: 1em; padding: 1em;\"><span style=\"color: #000000; font-size: 18pt;\">The Three Roles of Windings in Motors<\/span><\/h3>\n<p>Winding performs the following three critical roles in a motor.<\/p>\n<p><strong>[The Three Roles of Winding]<\/strong><\/p>\n<ul>\n<li>Generating a magnetic field by passing electric current<\/li>\n<li>Controlling the strength and distribution of the magnetic field to determine torque and rotational speed<\/li>\n<li>Properly dissipating the heat generated (copper loss)<\/li>\n<\/ul>\n<p>Since the strength of the magnetic field varies depending on the number of turns and the configuration of the windings, they are the most critical factor determining a motor\u2019s performance. For example, increasing the number of turns strengthens the magnetic field and improves torque, but it also increases resistance. Additionally, performance characteristics can be adjusted based on the wire area product (wire diameter squared \u00d7 number of turns). In medical equipment and optical equipment, the precision of this winding design directly impacts product reliability.<\/p>\n<p>&nbsp;<\/p>\n<h3 style=\"color: #fff; background: #c3effa; line-height: 20px; font-size: 23px; margin: 10; padding-left: 1em; padding: 1em;\"><span style=\"color: #000000; font-size: 18pt;\">Performance Comparison of Copper and Aluminum Winding<\/span><\/h3>\n<p>The selection of winding material depends on the motor\u2019s application and the required performance. The main characteristics of copper and aluminum windings are shown below.<\/p>\n<table style=\"width: 100%; max-width: 100%; border-collapse: collapse;\">\n<tbody>\n<tr style=\"height: 23px;\">\n<td style=\"width: 20%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0Item<\/td>\n<td style=\"width: 34.0024%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Copper Winding<\/td>\n<td style=\"width: 24.9976%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Aluminum Winding<\/td>\n<\/tr>\n<tr style=\"height: 28px;\">\n<td style=\"width: 20%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">\u00a0Electrical Conductivity<\/td>\n<td style=\"width: 34.0024%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">High (resistivity 1.68\u00d710\u207b\u2078 \u03a9\u00b7m)<\/td>\n<td style=\"width: 24.9976%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Approx. 60% of copper<\/td>\n<\/tr>\n<tr style=\"height: 29.3408px;\">\n<td style=\"width: 20%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Specific gravity<\/td>\n<td style=\"width: 34.0024%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">8.9<\/td>\n<td style=\"width: 24.9976%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">2.7 (lightweight)<\/td>\n<\/tr>\n<tr style=\"height: 23px;\">\n<td style=\"width: 20%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0Cost<\/td>\n<td style=\"width: 34.0024%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">High<\/td>\n<td style=\"width: 24.9976%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Low<\/td>\n<\/tr>\n<tr style=\"height: 23px;\">\n<td style=\"width: 20%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Main Applications<\/td>\n<td style=\"width: 34.0024%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Compact, high-performance motors<\/td>\n<td style=\"width: 24.9976%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Large and automotive motors<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<div>\u00a0Copper windings have high electrical conductivity and are effective at minimizing losses (I\u00b2R), making them advantageous in terms of efficiency and temperature rise; they are the most common choice for motor applications. Copper windings are selected for <a href=\"https:\/\/cik-ele.com\/en\/column\/medicalpump\/\">medical and optical equipment<\/a>, where high performance and miniaturization are required. On the other hand, while aluminum windings are lightweight and cost-effective, they require a larger wire diameter to achieve equivalent performance. Aluminum windings are adopted in large industrial motors and automotive applications to reduce weight.<\/div>\n<div>\n<div><\/div>\n<\/div>\n<div>\n<h3 style=\"color: #fff; background: #c3effa; line-height: 20px; font-size: 23px; margin: 10; padding-left: 1em; padding: 1em;\"><span style=\"color: #000000; font-size: 18pt;\">Types of Insulation Coatings and Selection Criteria<\/span><\/h3>\n<p>The operating temperature of the environment is the most critical factor in selecting an insulation coating. The characteristics of the main insulation coatings are shown below.<\/p>\n<table style=\"width: 100%; max-width: 100%; border-collapse: collapse;\">\n<tbody>\n<tr style=\"height: 23px;\">\n<td style=\"width: 25%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0Type of Coating<\/td>\n<td style=\"width: 12%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Temperature Resistance<\/td>\n<td style=\"width: 14.8725%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0Heat Resistance Class<\/td>\n<td style=\"width: 45.1275%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Main Features and Applications<\/td>\n<\/tr>\n<tr style=\"height: 28px;\">\n<td style=\"width: 25%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Polyurethane (UEW)<\/td>\n<td style=\"width: 12%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">120\u2103<\/td>\n<td style=\"width: 14.8725%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Class E<\/td>\n<td style=\"width: 45.1275%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Direct soldering possible; suitable for compact motors<\/td>\n<\/tr>\n<tr style=\"height: 29.3408px;\">\n<td style=\"width: 25%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Polyester (PEW)<\/td>\n<td style=\"width: 12%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">155\u2103<\/td>\n<td style=\"width: 14.8725%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Class F<\/td>\n<td style=\"width: 45.1275%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Widely used in general-purpose motors<\/td>\n<\/tr>\n<tr style=\"height: 23px;\">\n<td style=\"width: 25%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Polyesterimide (EIW)<\/td>\n<td style=\"width: 12%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">180\u2103<\/td>\n<td style=\"width: 14.8725%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Class H<\/td>\n<td style=\"width: 45.1275%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Excellent heat resistance; used in heat-resistant general-purpose motors.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<div>\n<p>While polyurethane wire can be soldered directly and is suitable for compact motors, it is not suitable for high-temperature environments. Polyester wire is widely used in general-purpose motors and offers well-balanced characteristics. Polyester-imide wire has excellent heat resistance and delivers stable performance even during prolonged continuous operation. Selecting the appropriate insulation coating for the specific application is a critical factor that determines the motor\u2019s reliability and lifespan.<\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"color: #fff; background: #437ae8; line-height: 70px; font-size: 30px; margin: 10; padding-left: 1em; padding: 1em;\">Motor Winding Manufacturing Methods and Application-Specific Selection<\/h2>\n<p><img decoding=\"async\" class=\"alignnone size-medium wp-image-11082\" src=\"https:\/\/cik-ele.com\/wp-content\/uploads\/2026\/05\/ea4914b4bfde865042ddaef628456f11-1-540x304.jpg\" alt=\"WHAT ARE MOTOR WINDINGS? AN EXPLANATION OF TYPES, APPLICATIONS, AND DESIGN\" width=\"540\" height=\"304\" \/><\/p>\n<p>Motor windings involve various winding methods and manufacturing processes, and selection requires an understanding of their respective characteristics.<\/p>\n<p><strong>Topics Covered in This Section<\/strong><\/p>\n<ul>\n<li>Comparison of Characteristics: Distributed Winding, Concentrated Winding, and Coreless Winding<\/li>\n<li>Proper Use of Spindle, Flyer, and Nozzle Winding Methods<\/li>\n<li>Requirements for Windings Used in Medical Device Applications, Optical Equipment, and Security Equipment<\/li>\n<\/ul>\n<p>Below, we provide an easy-to-understand explanation of various winding methods, such as distributed and concentrated winding, as well as manufacturing methods like the spindle method and flyer method.<\/p>\n<p>&nbsp;<\/p>\n<h3 style=\"color: #fff; background: #c3effa; line-height: 20px; font-size: 23px; margin: 10; padding-left: 1em; padding: 1em;\"><span style=\"color: #000000; font-size: 18pt;\">Comparison of Characteristics Between Distributed Winding, Concentrated Winding, and Coreless Winding<\/span><\/h3>\n<p>Motor performance characteristics vary significantly depending on the winding method. The characteristics of the three main methods are shown below.<\/p>\n<table style=\"width: 100%; max-width: 100%; border-collapse: collapse;\">\n<tbody>\n<tr style=\"height: 23px;\">\n<td style=\"width: 13.6762%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Winding Method<\/td>\n<td style=\"width: 27.3238%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Characteristics<\/td>\n<td style=\"width: 25%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0Advantages<\/td>\n<td style=\"width: 25%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Main Applications<\/td>\n<\/tr>\n<tr style=\"height: 28px;\">\n<td style=\"width: 13.6762%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Distributed Winding<\/td>\n<td style=\"width: 27.3238%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Winding distributed across multiple slots<\/td>\n<td style=\"width: 25%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Uniform magnetic field<br \/>\nLow torque ripple<br \/>\nReduced vibration and noise<\/td>\n<td style=\"width: 25%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Large industrial motors<br \/>\nmedical equipment<\/td>\n<\/tr>\n<tr style=\"height: 29.3408px;\">\n<td style=\"width: 13.6762%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Concentrated winding<\/td>\n<td style=\"width: 27.3238%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Concentrated windings on a single tooth<\/td>\n<td style=\"width: 25%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">High production efficiency<br \/>\nLess copper wire used<br \/>\nCost reduction<\/td>\n<td style=\"width: 25%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Automotive Motors<br \/>\nCompact motors<\/td>\n<\/tr>\n<tr style=\"height: 23px;\">\n<td style=\"width: 13.6762%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Core-less winding<\/td>\n<td style=\"width: 27.3238%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Core-less structure<\/td>\n<td style=\"width: 25%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Zero cogging torque<br \/>\nhigh-speed responsiveness<br \/>\nSmooth rotation<\/td>\n<td style=\"width: 25%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0medical equipment<br \/>\noptical equipment<br \/>\nPrecision equipment<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<p>In distributed winding, the windings are distributed across multiple slots (grooves in the iron core), resulting in a uniform magnetic field. This minimizes torque ripple and is effective in suppressing vibration and noise. On the other hand, in concentrated winding, the windings are concentrated on a single tooth (a protrusion on the iron core). This structure simplifies the winding process, leading to high production efficiency, and reduces costs by minimizing the amount of copper wire used.Core-less winding, which does not use a core, produces almost no cogging, enabling smooth rotation, and features a low moment of inertia and excellent high-speed responsiveness. Thanks to these characteristics, C.I. Takiron Corporation\u2019s core-less motors are well-suited for precision applications such as medical equipment and optical equipment.<\/p>\n<p>&nbsp;<\/p>\n<h3 style=\"color: #fff; background: #c3effa; line-height: 20px; font-size: 23px; margin: 10; padding-left: 1em; padding: 1em;\"><span style=\"color: #000000; font-size: 18pt;\">Selecting Between Spindle, Flyer, and Nozzle Winding Methods<\/span><\/h3>\n<p>The selection of the manufacturing method depends on the coil shape, production volume, and precision requirements.<\/p>\n<p><strong>\u00a0[Main Manufacturing Methods]<\/strong><\/p>\n<ul>\n<li>Spindle Method: Copper wire is wound around a high-speed rotating shaft<\/li>\n<li>Flyer method: A flyer (arm) rotates relative to a fixed core<\/li>\n<li>Nozzle Winding: Achieves precise winding using specialized machinery<\/li>\n<\/ul>\n<p>The spindle method involves winding copper wire around a high-speed rotating shaft and is suitable for high efficiency mass production. The flyer method, in which a flyer (arm) rotates relative to a fixed core, can handle complex shapes and large-diameter coils and is primarily used for rotor windings in commutator motors.<\/p>\n<p>Additionally, nozzle winding, which uses specialized machinery to perform precise winding, is a leading choice for medical equipment and optical equipment that requires high precision. The varnish treatment applied after winding not only prevents deformation caused by vibration and heat but also serves to improve mechanical strength and insulation performance.<\/p>\n<p>&nbsp;<\/p>\n<h3 style=\"color: #fff; background: #c3effa; line-height: 20px; font-size: 23px; margin: 10; padding-left: 1em; padding: 1em;\"><span style=\"color: #000000; font-size: 18pt;\">Winding Requirements for Medical Device Applications, Optical Equipment, and Security Equipment<\/span><\/h3>\n<p>Understanding the winding requirements for each application enables motor selection. The requirements for major fields are listed below.<\/p>\n<table style=\"width: 100%; max-width: 100%; border-collapse: collapse;\">\n<tbody>\n<tr style=\"height: 23px;\">\n<td style=\"width: 17%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Field<\/td>\n<td style=\"width: 11.6186%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0Required Performance<\/td>\n<td style=\"width: 26.3814%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Technical Requirements<\/td>\n<td style=\"width: 27%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">C.I. Takiron Corporation&#8217;s Solutions<\/td>\n<\/tr>\n<tr style=\"height: 28px;\">\n<td style=\"width: 17%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">\u00a0medical equipment<\/td>\n<td style=\"width: 11.6186%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">High-precision control<\/td>\n<td style=\"width: 26.3814%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">cogging-free<br \/>\nLow vibration, low noise, and long service life<\/td>\n<td style=\"width: 27%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Smooth rotation achieved with Coreless motors<\/td>\n<\/tr>\n<tr style=\"height: 29.3408px;\">\n<td style=\"width: 17%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">optical equipment<\/td>\n<td style=\"width: 11.6186%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">High-speed AF<br \/>\nImage stabilization<\/td>\n<td style=\"width: 26.3814%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">High-speed responsiveness (in milliseconds)<br \/>\nPositioning accuracy (micrometer order)<\/td>\n<td style=\"width: 27%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">\u00a0Precise control with high-response Coreless motors<\/td>\n<\/tr>\n<tr style=\"height: 23px;\">\n<td style=\"width: 17%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">security equipment<\/td>\n<td style=\"width: 11.6186%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Battery-powered<br \/>\nlong service life<\/td>\n<td style=\"width: 26.3814%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Low-voltage operation (1.0 V to 3.0 V)<br \/>\nEnergy-saving<\/td>\n<td style=\"width: 27%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Models available that operate at a minimum of 1.0V<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Medical equipment requires smooth rotation with virtually no cogging torque, high-precision speed control, low vibration and low noise, and a long service life.Optical equipment requires high-speed responsiveness and positioning accuracy for camera autofocus and lens drive. For security equipment, low-voltage operation (1.0V\u20133.0V) and long service life (reducing battery replacement frequency) are critical. C.I. Takiron Corporation\u2019s Micromotors include models that operate at a minimum of 1.0V, providing optimal solutions tailored to the demands of each field.<\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"color: #fff; background: #437ae8; line-height: 70px; font-size: 30px; margin: 10; padding-left: 1em; padding: 1em;\">Motor Winding Resistance Measurement and Design Optimization<\/h2>\n<p><img decoding=\"async\" class=\"alignnone size-medium wp-image-11084\" src=\"https:\/\/cik-ele.com\/wp-content\/uploads\/2026\/05\/2ff75cc3bf0ba74b138890adf3385df6-540x304.jpg\" alt=\"WHAT ARE MOTOR WINDINGS? AN EXPLANATION OF TYPES, APPLICATIONS, AND DESIGN\" width=\"540\" height=\"304\" \/><\/p>\n<p>The resistance value of motor windings is the most important indicator for evaluating motor performance and quality.<\/p>\n<p><strong>Topics covered in this section<\/strong><\/p>\n<ul>\n<li>Formulas for calculating winding resistance and measurement methods<\/li>\n<li>Resistance changes due to temperature rise and thermal design<\/li>\n<li>Optimization of winding design and customization for specific applications<\/li>\n<\/ul>\n<p>Winding resistance is determined by the length, wire diameter, and electrical resistivity of the material, and directly affects the motor\u2019s electric current, torque, heat generation, and efficiency. During the manufacturing process, continuity tests and resistance measurements are performed, and tolerance limits are set according to product specifications, standards, and manufacturer criteria. As a guideline, some cases manage resistance values within approximately \u00b110%.Additionally, since the resistance of copper wire increases by approximately 4% for every 10\u00b0C rise in temperature , appropriate cooling design is essential. The design process comprehensively optimizes winding materials, number of turns, wire diameter, winding method, insulation coating, and thermal management according to the specific application.<\/p>\n<p>&nbsp;<\/p>\n<h3 style=\"color: #fff; background: #c3effa; line-height: 20px; font-size: 23px; margin: 10; padding-left: 1em; padding: 1em;\"><span style=\"color: #000000; font-size: 18pt;\">Formula for Calculating Winding Resistance and Measurement Methods<\/span><\/h3>\n<p>Accurate understanding and measurement of winding resistance are essential for motor quality control. Winding resistance R is calculated using the following formula.<\/p>\n<p>[Formula for Winding Resistance]<\/p>\n<p>R = \u03c1 \u00d7 L \/ A<\/p>\n<p>\u03c1: Electrical resistivity of the material (\u03a9m)<\/p>\n<p>L: Length of the conductor (m)<\/p>\n<p>A: Cross-sectional area of the wire (m\u00b2)<\/p>\n<p>Increasing the number of turns increases the winding length L, raising the resistance, while increasing the wire diameter increases the cross-sectional area A, lowering the resistance. For example, when comparing copper wires with diameters of 0.1 mm and 0.2 mm with the same number of turns, the resistance of the latter\u2014which has four times the cross-sectional area\u2014is calculated to decrease to approximately one-fourth that of the former.<\/p>\n<p>After the winding is complete, the resistance is measured using a digital multimeter or milliohmmeter to verify that it matches the design value. Additionally, testing the insulation performance through a withstand voltage test is an essential step in quality assurance. At C.I. Takiron Corporation, we ensure high reliability under strict quality control.<\/p>\n<p>&nbsp;<\/p>\n<h3 style=\"color: #fff; background: #c3effa; line-height: 20px; font-size: 23px; margin: 10; padding-left: 1em; padding: 1em;\"><span style=\"color: #000000; font-size: 18pt;\">Resistance Changes Due to Temperature Rise and Thermal Design<\/span><\/h3>\n<p>Temperature rise during motor operation significantly affects performance and lifespan. Copper wire has a temperature coefficient of 0.004\/\u00b0C, meaning that a 10\u00b0C increase in temperature causes the resistance to rise by approximately 4%.<\/p>\n<table style=\"width: 100%; max-width: 100%; border-collapse: collapse;\">\n<tbody>\n<tr style=\"height: 23px;\">\n<td style=\"width: 20%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0Temperature (\u00b0C)<\/td>\n<td style=\"width: 21.5938%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0Temperature (\u00b0C)<\/td>\n<td style=\"width: 37.4062%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Impact on Efficiency<\/td>\n<\/tr>\n<tr style=\"height: 28px;\">\n<td style=\"width: 20%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">\u00a025\u00b0C (Reference)<\/td>\n<td style=\"width: 21.5938%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">100%<\/td>\n<td style=\"width: 37.4062%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Standard<\/td>\n<\/tr>\n<tr style=\"height: 29.3408px;\">\n<td style=\"width: 20%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">50\u2103<\/td>\n<td style=\"width: 21.5938%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Approx. 110%<\/td>\n<td style=\"width: 37.4062%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Copper loss (I\u00b2R) increases by approximately 10%<\/td>\n<\/tr>\n<tr style=\"height: 23px;\">\n<td style=\"width: 20%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">75\u2103<\/td>\n<td style=\"width: 21.5938%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0Approx. 120%<\/td>\n<td style=\"width: 37.4062%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Copper loss (I\u00b2R) increases by approx. 20%<\/td>\n<\/tr>\n<tr style=\"height: 23px;\">\n<td style=\"width: 20%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">100\u2103<\/td>\n<td style=\"width: 21.5938%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Approx. 130%<\/td>\n<td style=\"width: 37.4062%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Copper loss (I\u00b2R) increases by approximately 30%<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Since the rate of efficiency loss varies depending on the ratio of copper loss to total loss, the table above should be treated as a guideline for the increase in copper loss. During motor operation, copper loss occurs due to the current flowing through the windings, leading to heat generation; as the temperature rises, the resistance increases, and efficiency decreases.<\/p>\n<p>In high-temperature environments or under high-load operation, it is essential to select insulation coatings with excellent heat resistance, such as polyester imide wire, and to incorporate cooling designs such as heat sinks or fan cooling. Additionally, varnish treatment is used to secure the windings and prevent deformation caused by thermal expansion*. Since a 10\u00b0C drop in temperature approximately doubles the lifespan, proper thermal design directly contributes to achieving a long service life for the motor.<\/p>\n<p>*We offer products that utilize a bonding method for this purpose.<\/p>\n<p>&nbsp;<\/p>\n<h3 style=\"color: #fff; background: #c3effa; line-height: 20px; font-size: 23px; margin: 10; padding-left: 1em; padding: 1em;\"><span style=\"color: #000000; font-size: 18pt;\">Optimization of Winding Design and Customization by Application<\/span><\/h3>\n<p>Optimizing winding designs for specific applications maximizes motor performance. The following outlines design guidelines for major applications.<\/p>\n<table style=\"width: 100%; max-width: 100%; border-collapse: collapse;\">\n<tbody>\n<tr style=\"height: 23px;\">\n<td style=\"width: 17%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">\u00a0Application<\/td>\n<td style=\"width: 20.0482%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Winding Method<\/td>\n<td style=\"width: 19.9518%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Wire Gauge Trends<\/td>\n<td style=\"width: 23%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Typical Number of Turns<\/td>\n<td style=\"width: 64%; background-color: #f0fff8; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Design Objective<\/td>\n<\/tr>\n<tr style=\"height: 28px;\">\n<td style=\"width: 17%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">high torque<br \/>\n\uff08industrial tools\uff09<\/td>\n<td style=\"width: 20.0482%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Brushed DC (stacked or wave-wound) and concentrated-wound <a href=\"https:\/\/cik-ele.com\/en\/column\/bldcmotor\/\">brushless DC<\/a> are the mainstream<\/td>\n<td style=\"width: 19.9518%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Select thicker wire based on the allowable electric current<\/td>\n<td style=\"width: 23%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Increase the number of turns to raise Kt (torque constant)<\/td>\n<td style=\"width: 64%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 28px;\">Maximizing magnetic flux density while balancing copper losses and heat generation<\/td>\n<\/tr>\n<tr style=\"height: 29.3408px;\">\n<td style=\"width: 17%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">High-speed rotation<br \/>\n(Precision equipment)\uff09<\/td>\n<td style=\"width: 20.0482%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Many concentrated windings<\/td>\n<td style=\"width: 19.9518%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">\u00a0Select fine wire or parallel winding to suppress the skin effect<\/td>\n<td style=\"width: 23%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">\u00a0Aim to reduce the number of turns to lower Ke (<a href=\"https:\/\/cik-ele.com\/en\/column\/back-emf\/\">back-EMF<\/a> constant)<\/td>\n<td style=\"width: 64%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 29.3408px;\">Reduction of electrical time constant<\/td>\n<\/tr>\n<tr style=\"height: 23px;\">\n<td style=\"width: 17%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">High-precision control<br \/>\n(Medical\/Optical)<\/td>\n<td style=\"width: 20.0482%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Core-less winding<\/td>\n<td style=\"width: 19.9518%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Selected with consideration for the mechanical strength of the coil<\/td>\n<td style=\"width: 23%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Flexible design due to low inductance<\/td>\n<td style=\"width: 64%; background-color: #ffffff; padding-top: 2px; padding-bottom: 4px; border: 1px solid #999999; height: 23px;\">Elimination of cogging torque and smooth rotation<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>For high torque applications such as industrial tools, magnetic flux density is increased by using thicker wire gauges and higher turn counts. Conversely, for high-speed rotation applications such as precision instruments, designs that minimize the number of turns to reduce back EMF are common.In medical and optical equipment, cogging-free coreless windings are prioritized to achieve high-precision control. At C.I. Takiron Corporation, we listen carefully to the specific requirements of each application and provide comprehensive support from small-lot prototyping to mass production. Our technical staff works directly with you to propose the optimal solution for your challenges.<\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"color: #fff; background: #437ae8; line-height: 70px; font-size: 30px; margin: 10; padding-left: 1em; padding: 1em;\">Summary<\/h2>\n<p><img decoding=\"async\" class=\"alignnone size-medium wp-image-11086\" src=\"https:\/\/cik-ele.com\/wp-content\/uploads\/2026\/05\/c7887a92414f854a9067849a51b9bb02-9-540x304.jpg\" alt=\"WHAT ARE MOTOR WINDINGS? AN EXPLANATION OF TYPES, APPLICATIONS, AND DESIGN\" width=\"540\" height=\"304\" \/>\u30e2\u30fc\u30bf\u5dfb<\/p>\n<p>Motor windings are the core component that generates torque through the interaction of magnetic fields created by electric current.Copper or aluminum wire is used as the material, and heat resistance varies depending on the type of insulation coating. There are various options for winding methods and manufacturing processes, and appropriate selection based on the application is essential. Key requirements differ by field\u2014such as high-precision control and cogging-free operation for medical equipment, and high-speed responsiveness for optical equipment. Management of winding resistance and thermal design also significantly impact performance and reliability.<\/p>\n<p>At C.I. Takiron Corporation, we provide high-precision Micromotors utilizing coreless winding technology, backed by rigorous quality control and customization to meet specific requirements.<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"text-decoration: underline;\">Product Information &amp; Inquiries<\/span><\/p>\n<p>For more details on C.I. Takiron\u2019s micro motor products, please visit the website below.<\/p>\n<ul>\n<li><strong> Product Site:<\/strong><a href=\"https:\/\/cik-ele.com\/en\/\"> https:\/\/cik-ele.com\/en\/<\/a><\/li>\n<li><strong> Coreless Motors:<\/strong><a href=\"https:\/\/cik-ele.com\/en\/products\/list\/coreless-motors-en\/\"> https:\/\/cik-ele.com\/en\/products\/list\/coreless_motor\/<\/a><\/li>\n<li><strong> Brushless Motors:<\/strong><a href=\"https:\/\/cik-ele.com\/en\/products\/list\/brushless_motors-en\/\"> https:\/\/cik-ele.com\/en\/products\/list\/brushless_motor\/<\/a><\/li>\n<li><strong> Geared Motors:<\/strong><a href=\"https:\/\/cik-ele.com\/en\/products\/list\/gearheads-en\/\"> https:\/\/cik-ele.com\/en\/products\/list\/gearhead\/<\/a><\/li>\n<li><strong> Encoders:<\/strong><a href=\"https:\/\/cik-ele.com\/en\/products\/list\/encoders-en\/\"> https:\/\/cik-ele.com\/en\/products\/list\/encoder\/<\/a><\/li>\n<\/ul>\n<p>If you are having trouble selecting a small motor for your product development, please feel free to contact us via the inquiry form. Our technical staff will discuss your application and requirements with you and propose the optimal solution.<\/p>\n<ul>\n<li><strong> Inquiries:<\/strong><a href=\"https:\/\/cik-ele.com\/en\/contact\/\"> https:\/\/cik-ele.com\/en\/contact\/<\/a><\/li>\n<\/ul>\n<p>&nbsp;<\/p>\n","protected":false},"excerpt":{"rendered":"<p>One of the most critical factors determining a motor\u2019s performance is its \u201cwinding.\u201d Windings consist of conductors\u2014such as copper or aluminum wire\u2014wound into coils. When an electric current flows through them, they generate a magnetic field. Through interaction with other magnetic fields (such as those from permanent magnets or other windings), they produce the rotational force that drives the motor, making them the heart of the motor.In motors used across a wide range of fields\u2014from industrial motors to medical equipment, optical equipment, and security equipment\u2014the materials, types, winding methods, and design of the windings directly impact performance, efficiency, durability, and reliability. This article systematically explains the knowledge that B2B engineers need to know, ranging from the basic principles of motor&#8230;<\/p>\n","protected":false},"author":8,"featured_media":11081,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_themeisle_gutenberg_block_has_review":false,"footnotes":""},"categories":[172],"tags":[699,700,701,702,703,704,705,706,707,708],"class_list":["post-11073","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-column","tag-motor-windings","tag-windings","tag-copper-wire","tag-aluminum-wire","tag-insulation-coating","tag-copper-windings","tag-aluminum-windings","tag-coreless-windings","tag-resistance-value","tag-thermal-design"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.6 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>WHAT ARE MOTOR WINDINGS? AN EXPLANATION OF TYPES, APPLICATIONS, AND DESIGN\uff5cC.I. TAKIRON Corporation. Micro motor product site.<\/title>\n<meta name=\"description\" content=\"One of the most critical factors determining a motor\u2019s performance is its \u201cwinding.\u201d Windings consist of conductors\u2014such as copper or aluminum wire\u2014wound into coils. When an electric current flows through them, they generate a magnetic field. Through interaction with other magnetic fields (such as those from permanent magnets or other windings), they produce the rotational force that drives the motor, making them the heart of the motor.In motors used across a wide range of fields\u2014from industrial motors to medical equipment, optical equipment, and security equipment\u2014the materials, types, winding methods, and design of the windings directly impact performance, efficiency, durability, and reliability. This article systematically explains the knowledge that B2B engineers need to know, ranging from the basic principles of motor operation to material types, manufacturing methods, selection criteria by application, resistance measurement and management, and design optimization points. For engineers involved in motor design and product development, understanding winding technology is crucial for optimal motor selection and performance maximization.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/cik-ele.com\/en\/column\/motor-windings\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"WHAT ARE MOTOR WINDINGS? AN EXPLANATION OF TYPES, APPLICATIONS, AND DESIGN\uff5cC.I. TAKIRON Corporation. Micro motor product site.\" \/>\n<meta property=\"og:description\" content=\"One of the most critical factors determining a motor\u2019s performance is its \u201cwinding.\u201d Windings consist of conductors\u2014such as copper or aluminum wire\u2014wound into coils. When an electric current flows through them, they generate a magnetic field. Through interaction with other magnetic fields (such as those from permanent magnets or other windings), they produce the rotational force that drives the motor, making them the heart of the motor.In motors used across a wide range of fields\u2014from industrial motors to medical equipment, optical equipment, and security equipment\u2014the materials, types, winding methods, and design of the windings directly impact performance, efficiency, durability, and reliability. This article systematically explains the knowledge that B2B engineers need to know, ranging from the basic principles of motor operation to material types, manufacturing methods, selection criteria by application, resistance measurement and management, and design optimization points. For engineers involved in motor design and product development, understanding winding technology is crucial for optimal motor selection and performance maximization.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/cik-ele.com\/en\/column\/motor-windings\/\" \/>\n<meta property=\"og:site_name\" content=\"C.I. TAKIRON Corporation. 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AN EXPLANATION OF TYPES, APPLICATIONS, AND DESIGN | C.I. TAKIRON Corporation. Micro motor product site.\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/cik-ele.com\\\/en\\\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\\\/\\\/cik-ele.com\\\/en\\\/column\\\/motor-windings\\\/#primaryimage\"},\"image\":{\"@id\":\"https:\\\/\\\/cik-ele.com\\\/en\\\/column\\\/motor-windings\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/cik-ele.com\\\/wp-content\\\/uploads\\\/2026\\\/05\\\/5-2.jpg\",\"datePublished\":\"2026-05-27T03:11:10+00:00\",\"dateModified\":\"2026-05-27T04:55:27+00:00\",\"description\":\"One of the most critical factors determining a motor\u2019s performance is its \u201cwinding.\u201d Windings consist of conductors\u2014such as copper or aluminum wire\u2014wound into coils. When an electric current flows through them, they generate a magnetic field. 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