The Stator Conductor section in Motor Wiz is essential because it directly affects the electrical performance, thermal behavior, and manufacturability of the motor. From a user perspective, this module allows motor designers and engineers to select conductor types, strand configurations, and insulation properties, and immediately visualize their impact on torque, losses, and efficiency. Understanding the conductor is critical for achieving optimal copper fill, minimal eddy current losses, and thermal management, which are all vital in EVs and industrial motors.

Motor Wiz provides a highly interactive interface where users can choose parameters such as coil style, number of strands, strand diameter, radial and tangential arrangement, insulator thickness, and overall conductor diameter. Each selection dynamically updates the simulation outputs, giving real-time feedback for design optimization.

 i. Coil Style   

• Form Wound:

• This refers to conductors that are pre-shaped and placed into the stator slots in a structured manner.

• Commonly used in medium to high-power motors where improved performance and reliability are required.

• Provides better control over insulation, ensuring higher dielectric strength and reducing electrical stress.

• Generally found in applications like traction motors, aerospace motors, and industrial high-power motors.

• Stranded:

• Involves multiple small strands of wire twisted together to form a larger conductor.

• Stranding reduces the skin effect (which causes higher resistance at higher frequencies), improving current distribution.

• It enhances mechanical flexibility, making it easier to wind in complex stator slot shapes.

• Commonly used in low to medium power applications, including electric vehicles and industrial machines.

 ii. Strands in Hand   

Refers to the number of individual strands of wire bundled together to form a single conductor. Commonly used in stranded conductors where multiple small wires are combined instead of a single thick wire.

Purpose:

• Reduces skin effect: High-frequency AC tends to concentrate near the surface of conductors; using multiple strands helps distribute the current more evenly.

• Reduces eddy current losses: By breaking the conductor into multiple strands, each insulated from the other, eddy currents are minimized.

• Increases flexibility: A stranded wire is more flexible than a solid conductor of the same cross-sectional area.

The number of strands varies based on the motor design and operating voltage.

 iii. Strand Diameter   

The SWGs and corresponding diameters:

 iv. Strands in Radial Direction   

If strands in radial direction = 1 (Single-strand conductor), the defining parameters are:

• Conductor Width: The total width of the single conductor that fits into the stator slot. It is a critical factor in determining the packing density and overall electrical performance.

• Conductor Height: The height of the single conductor, which influences the stator slot fill and the thermal dissipation properties.

If strands in radial direction > 1 (Multi-strand conductor), the defining parameters are:

• Strand Width: The width of individual strand making up the total conductor. Affects the distribution of current and reduces eddy current losses.

• Strand Height: The height of an individual strand. Plays a role in thermal management and mechanical flexibility within the stator slot.

 v. Strands in Tangential Direction   

If strands in tangential direction = 1 (Single-strand conductor), the defining parameters are:

• Conductor Width: The total width of the single conductor that fits into the stator slot. It is a critical factor in determining the packing density and overall electrical performance.

• Conductor Height: The height of the single conductor, which influences the stator slot fill and the thermal dissipation properties.

If strands in tangential direction > 1 (Multi-strand conductor), the defining parameters are:

• Strand Width: The width of individual strand making up the total conductor. Affects the distribution of current and reduces eddy current losses.

• Strand Height: The height of an individual strand. Plays a role in thermal management and mechanical flexibility within the stator slot.

 vi. Insulator Thickness   

• Definition: Thickness of the insulating material covering each strand of the conductor.

• Purpose:

• Prevents short circuits between adjacent strands and between coils.

• Provides thermal resistance, helping to withstand high operating temperatures.

• Affects the slot fill factor (percentage of slot area occupied by copper vs. insulation).

• Selection Factors:

• Higher voltage applications require thicker insulation to prevent dielectric breakdown.

• Thermal class of insulation material (e.g., Class F: 155°C, Class H: 180°C, Class C: lesser than 200°C).

 vii. Overall Conductor Diameter   

• Definition: The total diameter of the conductor including its insulation.

• Significance:

• Determines the packing density in the stator slots.

• Affects thermal dissipation and magnetic performance.