Record coil position, height and lead checks before potting. Export a traveler for review.
By CustomAxialFlux Engineering Editorial · Created · Reviewed
Record coil checks before potting. Try two simulated held slots.
Loading interactive worksheet…
0 checked pass · 0 flagged · 18 pending of 18 slots.
Next: complete the required setup below, or load the illustrative example. A blank worksheet is also available.
Go to slot checks ↓ · Download blank worksheetRequired setup: all fields and datum confirmation. All slot observations are required for a complete record. Results update immediately; no server request. Uniform angular spacing and a one-sided height maximum only. PASS means the entered checks passed; finished stator clearance and production release are outside this tool.
Changing coil count clears slot observations. Mid-annulus chord is illustrative; use drawing coordinates for manufacture.
Isolation selections record pass/fail against your approved procedure. No test voltage, test duration or resistance threshold is supplied by this worksheet. An insulating nest alone is not a valid test electrode.
| Slot | Nominal (°) | Measured Angle (°) | Measured Height Z (mm) | Lead Exit Channel | Nest Isolation per Plan | Verdict |
|---|---|---|---|---|---|---|
| Slot 1 | --° | PENDING | ||||
| Slot 2 | --° | PENDING | ||||
| Slot 3 | --° | PENDING | ||||
| Slot 4 | --° | PENDING | ||||
| Slot 5 | --° | PENDING | ||||
| Slot 6 | --° | PENDING | ||||
| Slot 7 | --° | PENDING | ||||
| Slot 8 | --° | PENDING | ||||
| Slot 9 | --° | PENDING | ||||
| Slot 10 | --° | PENDING | ||||
| Slot 11 | --° | PENDING | ||||
| Slot 12 | --° | PENDING | ||||
| Slot 13 | --° | PENDING | ||||
| Slot 14 | --° | PENDING | ||||
| Slot 15 | --° | PENDING | ||||
| Slot 16 | --° | PENDING | ||||
| Slot 17 | --° | PENDING | ||||
| Slot 18 | --° | PENDING |
Measured angles: 0 ≤ angle < 360° from Datum C; 359.98° is 0.02° from Slot 1 at zero. Positive heights only; no lower height limit is evaluated. Grey pending slots are not passing slots. Scroll the table horizontally on small screens.
Share the current observation record, fixture drawing and unresolved checks for a DFM scope review. Include the approved electrical procedure and fixture revision.
| Decision | Required evidence | When to hold |
|---|---|---|
| Locate from agreed datums | Drawing-defined axial plane, centering feature and angular zero; see datum concept and ASME scope [1]. | Fixture registration is unknown or differs from the drawing. |
| Separate pitch from height | Uniform slot angle and measured peak Z; see explicit geometry method below. | Any angle exceeds the entered tolerance, or peak Z exceeds the drawing maximum. |
| Check thermal fit in both directions | Material-grade coefficients and actual temperature; the tool is a free-expansion illustration [2]. | Binding, lost registration or unknown hot pocket clearance. |
| Keep electrical acceptance project-specific | Approved procedure and traceable test record; instrument guidance depends on the equipment [3]. | No suitable electrode path, missing procedure or failed observation. |
These are inspection planning decisions. Public sources support the method and boundaries; they do not demonstrate our fixture capability, a measured production tolerance or a qualified stator.
Use A to establish the axial measurement plane, B to center the annulus and C to identify Slot 1 and the positive angular direction. A round pilot leaves angular rotation free, so the index is a separate function. Avoid redundant rigid contacts that can deform a soft winding pack. This is a concept scheme; the designer must specify the actual datum features and restraint.
ASME Y14.43 addresses fixture and gage tolerance verification. Its public scope does not supply a coil-pocket flatness, draft angle or clamp load for this application. Read ASME’s scope [1] ↗
| Drawing feature | Add before fabrication | Inspection method to agree |
|---|---|---|
| A: axial seat | Seat flatness, support pattern, surface finish and zero-height definition. | Map the support plane with calibrated metrology. |
| B: pilot / center | Diameter, fit, axis relationship and allowance at process temperature. | Check centering and hot-fit behavior. |
| C: angular index | Index geometry, clockwise convention and winding map revision. | Verify Slot 1 and absolute slot angles from the index. |
| Pocket and bridge | Contact geometry, allowed compression, maximum Z and any lower limit. | Measure peak height and distortion with the specified clamp condition. |
| Lead comb | Lead bundle envelope, bend radius, insulation protection and seal design. | Inspect the complete routing path with cover and seals installed. |
For N equally spaced slots, the exact nominal step is 360/N degrees and Slot i is at (i−1) × 360/N. The calculation keeps full precision before comparison. It displays rounded values only for reading. Angles use the shortest circular difference, so a reading just below 360° can be close to Slot 1 at zero.
The displayed reference chord is 2r × sin(π/N), where r=(OD+ID)/4 is the mid-annulus radius. This is a geometric illustration, not the winding’s actual reference pitch circle. For OD 280 mm, ID 180 mm and N=18, r=115 mm, step=20° and reference chord≈39.939 mm. Nonuniform, skewed or layered winding coordinates require a dedicated inspection plan.
| State | Meaning | Next action |
|---|---|---|
| INCOMPLETE / INVALID | Missing required setup or slot observations, or values outside the model range. | Complete setup and measurements; use the blank worksheet if interactive entry is unavailable. |
| PITCH / HEIGHT | Absolute position or upper Z limit exceeded. | Re-seat, remeasure and review the drawing limits; do not average away a high spot. |
| LEAD / ISOLATION | At least one recorded observation failed. | Correct routing or investigate under the approved electrical plan; the displayed badge shows one priority issue per row. |
| Recorded checks pass | Every entered slot passes only the evaluated checks. | Review full drawing, metrology uncertainty and process criteria before project sign-off. |
Inputs accept positive geometry, 3–72 integer slots, angular tolerance below half a slot step and 0≤measured angle<360°. Temperature range −50 to 200°C is a model entry bound, not a material or process capability. The worksheet checks no lower height limit, flatness, coil width, gap between coils or 3D lead clearance.
Do not force an oversize coil below the height limit by tightening the fixture. Resolve the winding or seating fault and use drawing-defined hard stops and controlled contact loads. Take peak Z readings from the agreed datum and clamping condition, rather than using an average coil thickness. The upper limit must come from the approved assembly stack. A passing unpotted coil height does not establish the finished resin surface, rotor running clearance or bearing motion allowance.
No force estimate follows from this height screen. Ansys distinguishes topology and winding conventions; its note on forces on stator teeth cannot establish a rotor bearing load from displacement of a nonmagnetic coil. A topology-specific coupled model is needed for magnetic force predictions. Ansys topology scope [4] ↗
The illustration uses ΔD=D × (α_fixture−α_copper) × (T_preheat−T_ambient) × 10⁻⁶. A positive value means greater free fixture diameter growth; a negative value means copper grows more. Either sign can matter. Actual radial clearance requires the local pocket dimensions and restraint; for a simple radius, free radial growth is half the diameter change.
| Material model | Coefficient | Evidence / limitation |
|---|---|---|
| 6061 aluminum | 23.0 | Illustrative engineering assumption; replace with actual grade, temperature and supplier data. |
| P20 tool steel | 12.0 | Illustrative assumption; heat treatment and actual temperature range need confirmation. |
| Unfilled PEEK | 45.0 | Victrex 450G flow direction below 143°C [2]; not average isotropic expansion. |
| 316 stainless steel | 16.0 | Illustrative assumption; actual stock and operating interval need confirmation. |
| Invar 36 | 1.2 | Illustrative assumption; lower expansion is not automatically a closer match to copper. |
| Copper reference | 16.5 | Illustrative free-copper coefficient; insulated winding packs may behave differently. |
Example: a 280 mm aluminum reference diameter heated from 22°C to 85°C gives +0.115 mm differential diameter growth using these assumed coefficients. It does not prove a 0.115 mm loose pocket. Victrex reports different coefficients by direction and temperature; the tool blocks PEEK at 143°C and above. Datasheet, page 2 [2] ↗
Distinguish a dry positioning fixture from a sealed potting cavity. Springs, sliding locators or vacuum ports used for dry handling need separation from resin or an approved sealing design before exposure to liquid resin. Check each lead from coil body through comb, cover, seal and terminal transition. A visible free lead can still be pinched when a bridge or mold half closes. Use drawing-defined bend radius and contact geometry; this page supplies no universal wire-radius, seal-compression or spring-force value.
The worksheet stores a visual alignment observation. It cannot measure a bend radius, predict leak tightness or qualify a seal. For a failed observation, reroute the lead, inspect the enamel and recheck with the intended closure configuration.
Record the procedure revision and measurement-record ID before marking a slot’s isolation pass/fail. The approved plan must define voltage, duration, temperature correction, electrodes, connections, discharge and acceptance. Insulation resistance, dielectric withstand and inter-turn tests are different evaluations; one is not proof of all three.
An insulating nest alone supplies no conductive return path. A high resistance reading to such a support does not establish winding insulation integrity. Have qualified personnel use the approved configuration on a de-energized assembly. AEMC’s manual explains equipment-dependent voltage selection and test precautions; it does not establish a universal pre-potting limit. AEMC manual §§1.3 and 4.3.1 [3] ↗
Resistance or waveform imbalance may justify further investigation, but this tool cannot infer turn count, circulating current, torque ripple or heating from coil angular error alone. Winding connections, speed, induced voltage and branch impedance require separate analysis.
| Approach | Potential fit | Cost / mismatch risk and mitigation |
|---|---|---|
| Dedicated machined nest | Repeatable registration for a stable geometry. | Upfront tooling and revision cost; freeze datum and pocket drawing before machining. |
| Adjustable prototype fixture | Geometry is still changing. | More setup and inspection labor; document each locked adjustment and recheck registration. |
| Combined mold and locating features | Approved tooling can both locate and encapsulate. | Limited measurement access and release risk; prove closure, access and removal on trials. |
| Printed sacrificial or prototype nest | Low-volume fit investigation after material review. | Creep, surface and temperature uncertainty; validate dimensions and process compatibility before use. |
| Risk | Consequence | Recovery / alternative |
|---|---|---|
| Using sample values as drawing limits | False acceptance despite incomplete design data. | Reset the example and obtain the approved tolerance stack. |
| Nonuniform winding forced into uniform slot model | Incorrect nominal angles and false verdicts. | Use a drawing-specific coordinate sheet and optical/CMM inspection. |
| A single Z reading misses a tilted coil | Local high spot can escape screening. | Map multiple prescribed points; do not treat this worksheet as a flatness inspection. |
| Rigid cold fit does not survive heating | Binding or loose registration at process temperature. | Review grade-specific expansion, compliance and hot dimensional trials. |
| Flow load inferred from injection gauge pressure | Incorrect pocket or clamp sizing. | Determine actual pressure distribution and load path in a separate process review. |
| Incomplete traveler exported as release | Missing or failed checks reach potting. | Use the explicit hold status and require an independent project sign-off. |
These are constructed worksheet examples, not customer cases, shop trials or measured production results.
Assume 280/180 mm envelope, 20° uniform spacing, ±0.15° angular tolerance and 5.50 mm maximum height. The loadable example has Slot 5 at 5.62 mm and Slot 11 with a misaligned lead. With all other simulated checks entered, the tool shows 16 passing slots, 2 flagged slots and a defect hold. Re-seat Slot 5 and correct Slot 11; no production outcome is implied.
After entering a valid setup for 24 coils, blank slot fields remain pending. A 15° nominal step is a reference position, not a measurement. Exporting produces an incomplete hold record. Measure every slot and record observations before requesting release.
If a user selects PEEK and 160°C preheat, the constant-CTE illustration is withheld. Victrex 450G data change with temperature and direction [2]. Obtain the actual fixture grade’s data and evaluate the process separately; switching the dropdown to another material does not validate a PEEK fixture.
It compares recorded uniform slot angles and maximum coil heights with user-entered limits, and records lead alignment and isolation observations. It does not release a stator for production.
In the concept sketch, A is the axial seating plane, B is a centering pilot and C is the angular index. These labels must be mapped to the approved part and fixture drawing; the sketch is not a toleranced manufacturing drawing.
No. Angular pitch is the separation of coil reference directions around the axis; height is the axial Z envelope from Datum A. The worksheet checks absolute angular position and an upper height limit independently.
The angle model assumes N equally spaced reference positions, 360/N degrees apart. For staggered layers, skew or nonuniform layouts, use a drawing-specific coordinate inspection plan instead.
The chord uses the mid-annulus radius (OD+ID)/4 as a geometric illustration. The actual coil reference radius may differ. Use the drawing pitch circle for manufacturing coordinates.
Enter angles from zero up to but excluding 360 degrees, measured from Datum C in the drawing direction. The comparison uses the shortest angular distance: 359.98 degrees is 0.02 degrees from zero.
Enter the approved maximum Z envelope. No default manufacturing tolerance is claimed. This is a one-sided screen: low coils, flatness, tilt and finished stator thickness require separate controls.
No. The displayed value is an illustrative difference in free diameter growth using constant coefficients. Radial growth is half the diameter growth. Actual clearance depends on pocket geometry, restraint and temperature distribution.
The worksheet stops the constant-CTE PEEK model at 143°C. Victrex 450G data distinguish direction and temperature regimes. Use grade-specific data and a separate process review outside this simplified model.
Use the project-approved procedure for the specific winding insulation system and test configuration. This page prescribes no voltage or resistance threshold. Record the test-plan and measurement-record references before selecting pass or fail.
No. An insulating support alone does not establish a conductive measurement return. The approved test plan must define electrodes, connected components and accessible surfaces; a recorded pass is not independent verification.
No. They are explicitly illustrative input and decision examples. Example data remain marked as simulated after editing. Reset the worksheet to begin a project record.
A draft traveler is useful for resolving hold items. It includes pending and defect counts, per-slot verdicts and a hold status. Export is not permission to pot or release the assembly.
No. This page owns coil positioning, drawing datums and pre-potting inspection. Resin selection, flow simulation, cure, exotherm and final stator qualification belong in the approved potting process.
Provide the stator and fixture STEP/drawings, winding map, datum definitions, peak-height limits, lead and terminal interfaces, process temperatures, material grades, electrical test plan and held-slot traveler. Unknown dimensions, costs and process acceptance remain pending confirmation.
For the broader assembly and process scope, see coreless epoxy stator sub-assemblies. Confirm winding polarity separately with coil polarity testing.
Public references checked on . Only public scope or datasheet content is cited. No claim is made that paid standards were reviewed in full. Geometry equations are reproducible definitions; uncited numerical coefficients are explicitly illustrative assumptions.
Public scope of fixture/gage tolerance verification; does not prescribe the example dimensions or coil tolerances.
Page 2: flow-direction CLTE 45 ppm/K below 143°C and 120 ppm/K above; average CLTE differs. Supports model boundary, not fixture certification.
Sections 1.3 and 4.3.1: de-energized testing and voltage selection by equipment and rating. Not a universal pre-potting acceptance specification.
Topology and winding-current conventions. The stator-teeth force discussion does not validate a force estimate for an ironless coil fixture.
