Design and prototyping of a modular PMSM with conventional and segmented stator constructions

This paper presents the design and prototyping of a permanent magnet synchronous motor developed to compare an un-segmented stator with a circumferentially segmented alternative under identical boundary conditions. The segmentation concept was selected through a structured design workshop that focused on manufacturability, assembly and serviceability. Twelve laminated segments with V-shaped interfaces were produced, and 3D printed end caps were used to support winding on the open-slot geometry. The un-segmented stator achieved a slot fill factor of 30.8 per cent, and the segmented stator achieved 35.1 per cent due to the use of 1.6 mm conductors and improved winding access. Winding trials on the segmented stator confirmed easier conductor placement and tighter end turns. The work reports practical observations from the design and build stages and provides a prototype that can be used for future electrical and thermal testing of modular stator concepts.