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Tight assembly of stator windings with no insulation paper damage is a manufacturing challenge. We evaluate different sets of parts according to the following parameters: magnet wire thickness, stator slot smoothness, length of the straight magnet wire after the slot end, and type and amount of insulation cap at the end of the slot. These parameters have discrete values with small differences between them. The damage criterion is the decrease of the insulation paper breakdown voltage after assembly/disassembly of parts, assembled in a small set of designed experiments. Parameter values, i.e., levels at individual experiments are set by an orthogonal experiment matrix. Repetition of each experiment provides statistical significance. Data analysis shows that the additive model alone is not sufficient due to the high correlation of the parameters’ influences. We extend the model to include interparameter influences, which we model by adding a virtual parameter. The extended additive model generates parameter values that do not degrade the insulation paper breakdown voltage within the manufacturing process. These values are verified by repetitions of the control experiment.

For the development of new electric motor winding techniques a detailed knowledge in the currently used techniques is essential; therefore a review of the most commonly used winding techniques is provided in this paper, focusing on the winding of PMSM AC winding. To compare several different winding topologies and production techniques the two key parameters are presented with the mathematical model. These two parameters are the length of the straight part of the wire and the conductor diameter, from which the efficiency peak and motor power are calculated. These calculations are based on the model of the newly developed high pole pair number three phase wave winding topology - Elaphe type winding. The results can be used also in other PMSM winding topologies since they show the key important facts of the winding detail. In addition, the methodology can be adopted for any winding type.