The Test
As part of a formal IEEE qualification program, five prototype 11 kV resin-rich, form-wound stator coils were sent from Australian Winders to Kinectrics, one of the world’s most respected independent testing laboratories in Toronto, Canada.
To simulate harsh service conditions, four of the five coils were subjected to 500 thermal cycles between 40°C and 155°C. The fifth coil remained untouched, acting as a control for thermal accuracy. Following this, the thermally aged coils were pushed even further and exposed to 27.9 kV at 120°C for 250 continuous hours. These test parameters well exceeded the thresholds outlined in IEEE Std 1553-2002 “Schedule B” requirements.
Performance that Exceeds Expectations
Extensive diagnostic testing was conducted before and after testing, including partial discharge analysis, surface resistivity, capacitance, and corona inspection. All four coils passed the endurance benchmark with flying colours.
- No electrical degradation was found in coil performance throughout the entire test program.
- Even Coil #4, which showed minor PD activity post-endurance testing, remained structurally and electrically stable, proving the structural integrity of Australian Winders’ insulation system.
- All coils remained free of external corona discharge during both pre- and post-test inspections at 12.65 kV using UV imaging, confirming the effectiveness of the shielding and uniformity of the insulation system.
- Cross-sectional imaging revealed strong conductor alignment and bonding, with no signs of delamination or structural compromise.
- Turn and strand insulation showed no signs of movement or shorting. Voids found between strands were isolated and located outside any high-stress areas, making them non-critical.
Made by Winders, for Winders
The final report concluded Australian Winders’ resin-rich, form-wound coil design consistently meets and exceeds IEEE testing standards. Proving, once again, that Australian Winders’ coils are among the best-in-class motor winding materials being produced today.
Kinectrics’ testing underscored what Australian Winders has always prioritised: designing coils that reflect the real demands of the field. Every detail of the coils demonstrates the application of technical engineering expertise to on-site conditions, ultimately making results more dependable over time.
This is what sets Australian Winders apart. These coils aren’t built to a drawing – they’re built by winders who know the job. Designed to reduce downtime, enhance performance, and maximise asset longevity, they’re proof that experience with coils matters.
If you’re looking for coils that do more than meet a spec sheet, upgrade with Australian Winders today.