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Ray,
From everything I have read, any wire not going through the slots, is really just waste. The end turns add nothing to the motor except weight, but they have to be there. Compressing them is necessary ONLY to get the wound stator back into the case. This is why on cheap motors like the AQ, that do not have a lot of wire and a lot of room inside the case, the winding is not compressed. The straighter the wire is inside the slots, and the shorter the end turns, the better.
Not compressing eliminates one step in the manufacturing process, so makes the motor cheaper to build. Plus not compressing eliminates the risk of causing a short because the wire is not mashed down on the stator and all it's sharp edges. Plus, it takes a good bit of special tooling to be able to compress, and not scratch or mess-up the wire. I'll spend almost a full day making the tooling, and it takes about 30 seconds to do the pressing.
Only when trying to get the most copper, into the smallest package, is there a need to compress.
Also, a Y wind usually takes up more room in the back end of a motor. Especially in a low turn wind like a 2Y. Reason being that Y connection can get pretty big, and takes up a lot of space. For instance in the AQ motor, there are 30 strands of .0105" wire in each of the three leads, and all three have to come together to make the Y, so there are 90 wires in that connection. It's tiny wire so even at 90, it doesn't look all that big.
So lets take a Neu 1515 1Y 2200 for example. They call it a 1Y but for the life of me I don't know why. The wire makes two passes through the slots, and to me that makes it a 2. This is the exact same wind that the AQ 2030 uses, and also what the dyna 1500 uses, and they are both called a 2????? Just more electronics confusion I guess.
But back to the point. The Neu 1515 2y has 40 strands in each leg, and the wire is pretty big at around .020 IIRC. So there are 120 strands in the Y connection, and it's BIG and has to be pressed down into the end turns on the rear of the motor. That takes up a lot of room. And that's why when comparing a Y with a D in the same motor brand and size. The Y will look "more full" than the delta looks. And the stator looks to be longer in the Y, it's not, it just has that big lump of wire on top of the end turns. And the Delta looks like they have some room left over inside that they did not fill.
Now lets wind that same 1515 motor, but make it a delta and all that wire in the Y is now brought out as the leads. And with a 2 delta, the leads would have 80 strands in each one and that would be huge, especially when compared to lets say a 6 Y. We know from the 2Y, that the slots will hold 80 strands of wire, remember it has two passes 40 per pass. So for the 6 Y, lets take that 80 and divide by 6 because this wind will have 6 passes (turns) of the bundle, through each slot. 80 divided by 6 is 13.333333, and you'll be really luck if you can get 13 through there. I'd try 12, it's always easy..... until the last pass, and then you find out that 13 won't fit! But if you leave out just one strand, it's actually 6 strands that won't be in the slot! So you want to keep as much as you can in the bundles, but it becomes a compromise between filling it up and how much frustration you can take, because the more wire you use, the winding process gets harder and harder. As you can see even just one strand makes a huge difference. But to sum it up, now our 6Y is finished and the lead wires look pathetic what with only 12 strands in each one. And compared to the 2y at 40 strands and the 2D at 80 strands, it looks like the 6Y got cheated out of a lot of wire. But actually on the inside, they all have very close to the same amount.
From everything I have read, any wire not going through the slots, is really just waste. The end turns add nothing to the motor except weight, but they have to be there. Compressing them is necessary ONLY to get the wound stator back into the case. This is why on cheap motors like the AQ, that do not have a lot of wire and a lot of room inside the case, the winding is not compressed. The straighter the wire is inside the slots, and the shorter the end turns, the better.
Not compressing eliminates one step in the manufacturing process, so makes the motor cheaper to build. Plus not compressing eliminates the risk of causing a short because the wire is not mashed down on the stator and all it's sharp edges. Plus, it takes a good bit of special tooling to be able to compress, and not scratch or mess-up the wire. I'll spend almost a full day making the tooling, and it takes about 30 seconds to do the pressing.
Only when trying to get the most copper, into the smallest package, is there a need to compress.
Also, a Y wind usually takes up more room in the back end of a motor. Especially in a low turn wind like a 2Y. Reason being that Y connection can get pretty big, and takes up a lot of space. For instance in the AQ motor, there are 30 strands of .0105" wire in each of the three leads, and all three have to come together to make the Y, so there are 90 wires in that connection. It's tiny wire so even at 90, it doesn't look all that big.
So lets take a Neu 1515 1Y 2200 for example. They call it a 1Y but for the life of me I don't know why. The wire makes two passes through the slots, and to me that makes it a 2. This is the exact same wind that the AQ 2030 uses, and also what the dyna 1500 uses, and they are both called a 2????? Just more electronics confusion I guess.
But back to the point. The Neu 1515 2y has 40 strands in each leg, and the wire is pretty big at around .020 IIRC. So there are 120 strands in the Y connection, and it's BIG and has to be pressed down into the end turns on the rear of the motor. That takes up a lot of room. And that's why when comparing a Y with a D in the same motor brand and size. The Y will look "more full" than the delta looks. And the stator looks to be longer in the Y, it's not, it just has that big lump of wire on top of the end turns. And the Delta looks like they have some room left over inside that they did not fill.
Now lets wind that same 1515 motor, but make it a delta and all that wire in the Y is now brought out as the leads. And with a 2 delta, the leads would have 80 strands in each one and that would be huge, especially when compared to lets say a 6 Y. We know from the 2Y, that the slots will hold 80 strands of wire, remember it has two passes 40 per pass. So for the 6 Y, lets take that 80 and divide by 6 because this wind will have 6 passes (turns) of the bundle, through each slot. 80 divided by 6 is 13.333333, and you'll be really luck if you can get 13 through there. I'd try 12, it's always easy..... until the last pass, and then you find out that 13 won't fit! But if you leave out just one strand, it's actually 6 strands that won't be in the slot! So you want to keep as much as you can in the bundles, but it becomes a compromise between filling it up and how much frustration you can take, because the more wire you use, the winding process gets harder and harder. As you can see even just one strand makes a huge difference. But to sum it up, now our 6Y is finished and the lead wires look pathetic what with only 12 strands in each one. And compared to the 2y at 40 strands and the 2D at 80 strands, it looks like the 6Y got cheated out of a lot of wire. But actually on the inside, they all have very close to the same amount.
Nortavlag Bulc 
got the temp gage and was amazed to see 215*F. I was very happy about no smoke, but nervous that I had hurt the motor.
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