Assembling rotor and armature windings

This standard identifies the competences you need to assemble rotor and armature windings, in accordance with approved procedures. This will involve selecting the correct components and materials, fitting and insulating components and fitting and terminating the coil. You will be required to select the appropriate tools and equipment to use, based on the operations to be performed and type of components to be fitted and to check that they are in a safe and serviceable condition. In carrying out the operations, you will be required to follow laid-down procedures and specific assembly techniques. The assembly activities will also include making all necessary checks and adjustments to ensure that components are correctly positioned and free from damage.

Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken and to report any problems with the assembly activities, components or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying assembly techniques and procedures to rotor and armature windings. You will understand the rotor or armature being assembled and its application and will know about the assembly techniques, tools and methods, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when carrying out the assembly operations. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.

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P1    work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines 

P2    follow the relevant instructions, assembly drawings and any other specifications

P3    ensure that the specified components and tools are available and that they are in a usable condition in preparation for assembly 

P4    assemble the components in their correct positions using appropriate methods and techniques

P5    secure the components using the specified connectors and securing devices

P6    check the completed assembly to ensure that all operations have been completed and it meets the required specification

P7    deal with problems within your control and report those that cannot be solved

P8    complete and store all relevant documentation in accordance with organisational requirements 

P9    leave the work area in a safe condition on completion of the activities, as per organisational requirements

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K1    how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines  

K2    the importance of wearing the appropriate personal protective equipment (PPE), and of keeping the work area clean and tidy 

K3    how to obtain and interpret drawings, planning sheets and records and other documents needed for the assembly activities

K4    the basic operating principles of the rotor and armatures being assembled

K5    the factors to consider when choosing pre-formed coils

K6    the assembly methods and techniques to be used when assembling rotating equipment rotor/armature windings

K7    the common types of winding configuration used for rotor/armature assembly

K8    the methods used to fit slot insulators

K9    the purpose of insulation cuffs

K10    the factors that determine the wedge length, width, squareness and profile

K11    the methods used to mark out and cut materials for the manufacture and trimming of wedges

K12    the methods used to fit wedges into slots

K13    the methods used to splice windings and the factors that affect the pitch of coils

K14    the procedure for protecting coil ends

K15    the common methods of attaching rotor/armature windings to the commutator

K16    the method used to check the electrical integrity of joints

K17    the methods used to apply insulating varnish and the types used

K18    the visual checks and preparation requirements for components to be used in electrical assembly activities

K19    the methods and tools/equipment used to transport, handle and lift the components into position 

K20    how to check that the tools/equipment are within current certification dates, free from damage and defects, in a safe and usable condition, and configured correctly for purpose

K21    the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

K22    how to access, use and maintain information to comply with organisational requirements and legislation

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1. Assemble the rotor and armature windings by carrying out all of the following activities:
   1. use the correct assembly drawings, specifications and job instructions
   2. adhere to health and safety regulations, systems and procedures to realise a safe system of work
   3. ensure that components are free from damage, foreign objects, dirt or other contamination
   4. check that all tools and equipment are within calibration date, where appropriate
   5. use safe and approved techniques to assemble and connect rotor/armature components
   6. leave the work area in a safe and tidy condition
2. Prepare and assemble windings using all of the following:
   1. rotor/armature wires
   2. slot wedges
   3. brazing materials
   4. preformed coils
   5. dummy coils
   6. solders
   7. insulating materials
   8. equaliser rings
   9. fluxes
   10. separating strips
   11. resin/glass bonding tapes
3. Use all of the following equipment and tools for the assembly operations:
   1. tinning and soldering equipment
   2. drying and baking ovens
   3. lathes
   4. multimeters
   5. insulating resin baths
   6. shaft supports
   7. impedance testers
   8. coil winding machines
4. Use all of the following assembly procedures:
   1. prepare components (such as coil ends, wedge length, width,  squareness and profile)
   2. insulate (such as slot, shaft, end winding support)
   3. secure windings (such as main, auxiliary, lap, wave, duplex, triplex, multiplex)
   4. band end windings
   5. solder connections (such as risers, coil ends)
   6. check mechanical integrity
   7. check electrical integrity (such as continuity, insulation, voltage withstand)
5. Assemble rotating equipment to one of the following quality and accuracy standards:
   1. organisational drawings and procedures
   2. customer drawings and requirements
   3. current industry standards, codes of practice and procedures
   4. other international standards

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4

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2029

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Current

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Original

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Enginuity

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SEMEEE3-26

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians, Maintenance Team Technician, Manufacturing Technologies, Production and Process Engineers

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2124

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Engineering; electrical; electronic; assemble; rotor; armature; windings; coil; methods; equipment

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