Electric windings for brushless motors: precision and reliability for modern industry
Brushless motors are among the most advanced and versatile solutions available today for electric drive systems and automation. With no sliding contacts, they deliver high efficiency, quiet operation, and minimal maintenance, making them ideal for applications where precision is critical.
Performance requirements for high-efficiency electric windings for brushless motors
They are widely used in sectors such as:
- industrial and collaborative robotics, where micron-level repeatability and vibration-free motion are essential;
- light-duty automation, axis movement, and linear actuation systems, where space and weight constraints are key design factors;
- electric vehicles and micro-mobility solutions, where fast dynamic response and long operational life are required.
To ensure consistently high performance, these motors must be paired with precision-engineered electric windings for brushless motors. These windings must be tailored to the motor’s specific architecture, whether it features surface-mounted or interior permanent magnets, as well as the input voltage and type of inverter used. Only by aligning all these parameters can the full potential of brushless motor technology be realized in demanding industrial environments.
Electric windings for brushless motors: precision engineering and high-performance materials
The reliability of a brushless motor starts with the quality of its stator winding. This component must be designed to operate with high-frequency power electronics, withstand thermal variations, and ensure a consistent distribution of the rotating magnetic field.
At Zampolli Avvolgimenti, we meet these requirements by selecting only top-grade materials, including:
- double or triple-insulated enameled copper wire, ensuring dielectric strength even under high PWM modulation voltages;
- class H thermal insulation, compatible with the demanding environments of high-performance motors;
- thermosetting resin impregnation, which solidifies the winding, eliminates vibrations, and prevents partial discharge phenomena.
The result is a perfectly balanced winding, ready to operate in full synergy with advanced control systems, even in the most challenging industrial settings.
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Electric windings for brushless motors: why choose Zampolli
Choosing Zampolli Avvolgimenti means partnering with a company that designs each winding using Class H thermal-grade materials, carefully selected to withstand the electrical and thermal stress typical of brushless motor applications.
Every winding is crafted with expertly executed insulation of all copper coils, using specialized hand techniques. Each turn is precisely positioned both in the slot and at the coil head, avoiding overlap and turn-to-turn shorts, and ensuring safe, stable operation, even at high switching frequencies.
The production process concludes with rigorous end-of-line testing, performed using high-precision measuring instruments to ensure every winding meets the highest quality standards.
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We can produce a very wide range of asynchronous windings thanks to dedicated but flexible equipment.