One of the objectives in winding brushless motors is to make the windings as dense as possible. Put another way, you want as much copper around the teeth as possible. This allows you to improve power and efficiency.
I discuss two main themes in describing how to achieve this. The first is whether to use one thick strand or a number of thinner strands. Provided the strand is not too difficult to bend around the stator, my findings are that you will almost always achieve the greatest density with a single strand. Its also usually quicker & easier to wind. There may be circumstances where multiple thinner strands are better but you will usually only use multiple thinner strands where a single thick strand is too difficult to wind and you accept slightly lower efficiency.
The other theme presented is to do with technique and here is what I recommend:
1.1 Concentrate hard and be very NEAT
1.2 Try to wind strands so that they lie in the hollows between other strands (of the previous layer)
1.3 Avoid crossing over strands as much as possible
1.4 Use new wire and make sure it does not get kinks in it
1.5 Flatten strands between the teeth after each layer
1.6 'Overflow' onto the heads to gain an extra turn or two (as shown on my CDRom page)
1.7 Check for shorts between each phase and the stator before running the motor.
These 'rules' apply mainly to the sections between teeth of the stator. However, note that the gap between the stator and rotor is small on many motors so you may need to keep the 'inside' head neat as well.
This somewhat lengthy page now explains the reasons for the views expressed above and provides more practical advice. Please let me know if you have any comments or better techniques. I have some comments on Star vs Delta at the bottom of the page. Other pages relating to motors are as follows:
* Summary page (small and large motors)
* CD-Rom motors (easy construction) and Crocodile motors (high efficiency)
* Machining tips (more advanced advice)
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