Setting Tolerances
Use this screen to enter your preferred tolerances to override EASA's default values.

By default, Motor Winding Workbench will use tolerances that EASA's engineering team has found to be a good fit for most service centers. If your service center would like a tighter or looser tolerance, you can enter them here.

You can specify your unique tolerances for:

• Wire size
• Turn, span and connection
• Volts per coils maximum
• Air gap maximum
• Tooth maximum
• Core maximum
• Circular mils per amp
  • Class A insulation system
  • Class B insulation system
  • Class F/H insulation system

Tolerances will affect which options appear in the Selection Grid when the Calculate button is clicked, and what alarm conditions will be displayed. The Wire Size Tolerance will affect what wire size combinations will be available in the Wire Size Calculator.

CONFIGURE YOUR PREFERRED TOLERANCES

Limiting Wire Size Selection
Motor Winding Workbench has provisions for controlling the wire sizes that are used for the automatic calculation of the redesign. In addition, there is a Wire Size Calculator available from the redesign pages which will allow adjustment of the redesign wire size. On the original data entry page that at the bottom of the Redesign panel there are several Wire Size checkboxes.

SET YOUR PREFERRED WIRE SIZES

The AWG – Metric radio buttons will default to the same setting as the original wire. Placing a checkmark in the box will allow the button to be set the AWG or Metric for the redesign. The AWG and Metric radio buttons limit the type of wire the program will select. Either AWG or Metric may be selected. A combination of both AWG and Metric is not allowed.

Just below that are checkboxes for Only Available and for ½ sizes. For the Only Available option to function properly, the available wire sizes must first be set. On the tools menu is the Set Available Wire Sizes command. Selecting that command opens the available wire setup page.

A check mark next to the wire size indicates the wire size is available. The rows can be sorted by any column by clicking the column heading. Clicking again reverses the sort order top to bottom.

The radio buttons in the panel at the top allow only AWG or Metric wires to be displayed. Simply check the wires that are available or in stock and uncheck those that are not. As an example, suppose a service center has only full size AWG wires from #15 to #24. Select the All radio button, the select Clear All. Now select the AWG button and Checkmark the available wires. Click OK to save the settings.

Now, placing a checkmark in the Only Available box will result in only those size wires being selected for the redesign.

The ½ size checkbox will allow those sizes for the redesign. Of course, if ½ sizes are not marked as Available on the wire setup page, they will not be used if the Only Available box is checked.

Wire Size Calculator
Once the redesign has been calculated, it is often necessary to adjust the wire sizes and the resulting slot fill, which also affects current density. The program provides a Wire Size Calculator to assist in choosing the best wire combination. When a redesign page is active, select the Wire Size Calculator Icon or select Redesign > Wire Size command. The Calculator panel will be displayed.

Select AWG or Metric wire sizes. Enter any two appropriate wire sizes. Generally, the two wire sizes should differ by just one full AWG or Metric wire size. Click Recalculate and the list of wire combinations data will be displayed. The list is initially sorted by the percent column. The percentage is the difference between the circular mils per turn of the wire combination and the circular mils per turn target. The target is the value that would match the original winding, given the circuits and connection of the redesign. When necessary, the target value can be entered manually. When the desired row is selected, clicking the OK button will place the wire combination into the redesign and calculate the slot fill and current densities.

For details of the Wire Size calculator, see the Help for Redesign > Wire Size command.

This screen allows you to configure a wide range of preferences.

• Language - English or Spanish
• Redesign density (USA or Telsa-A/mm²)*
• Original density (USA or Telsa-A/mm²)*
• Default length unit (inches, mm, none)
• Default power unit (kW, hp, none)
• Default winding type (concentric, lap, none)
• Default connection type (delta, wye, none)
• Default core unit (tooth, slot, none)
• Default wire type (AWG, metric, none)
• Default frequency

* Select USA or Metric units for Original and for Redesign flux and current densities. Imperial units for flux density are line per square inch and Imperial current density units are circular mils per amp. Metric units for flux density are line per square centimeter and metric current density units are amps per square millimeter.

SET YOUR PREFERENCES

This feature is still under development.

Once available, EASA members will use this function to submit requests directly to Technical Support allowing EASA's engineering team to access your motor directly within Motor Winding Workbench. With this, the engineers can:

• See your data exactly as you've entered it and respond to your help request quicker
• Give guidance on your design
• Help edit your design
• Diagnose errors or tolerance messages you may be getting
• Verify winding data you've collected

IMPORTANT NOTE
EASA's current Data Verification & Redesign Request online web form will be removed once this function goes live. All winding verification & redesign requests MUST be submitted through Motor Winding Workbench.

To begin your database search, click on Motor Database in the main navigation menu, then click on the the type of motor:

• Three phase motors
• Multispeed motors
• Single phase motors
• DC motors

Motor Winding Workbench provides access to EASA's Motor Winding Database. The database has entries for:

• Three phase motors
• Multispeed motors
• Single phase motor
• DC motors

The database is updated regularly with new records provided by EASA members and EASA Technical Support Specialists.

On the right side of the database screens, you'll find the database filter tool which provides access to the filter criteria for each of the four motor types. If not already open, click the Filter icon  at the upper right to open the search criteria panel. The available search criteria differ for the four motor types; three-phase motor options are shown here.

The filter tool has entries for most of the values in the motor database records.

The %Tolerance (default 2%) is the first field on the filter tool and applies to the data entry fields highlighted in orange. If you've entered a different % Tolerance in the preferences, that value will be used. At any time, you may enter a new value here. This percentage is used to compare the entered values to those in the database.

SET YOUR PREFERRED TOLERANCES

The filter tool will attempt to match all entered values with records in the database for the selected motor type. Entering the least amount of search criteria will produce the best results. All the entered fields must match records in the database for them to be displayed. Entering data in too many search fields may return no data. Searching on core dimension, slots and poles works well. 

Once all relevant filter criteria are entered, you MUST click Motor Count located at the bottom of the filter panel.

If too many motors match the criteria, "The request payload is too large" is displayed. Enter additional criteria to restrict the number of motors found. 

If the number of results is within reason, click Show Motors located at the bottom of the filter panel to display a table of the matching records.

The Reset icon  at the bottom will clear all search criteria to start a new search.

To increase the number of motor results visible in the table, use the Rows per page function at the bottom left of the results table.

Here is an example of the table of results of motors matching the filter criteria (click image to enlarge).

Sorting the results
The table can be sorted by clicking the column headers; clicking again reverses the sort order top to bottom. 

Table viewing options (Table actions)
The software allows you to view additional information about the filtered results as well as reorder the columns to best meet your needs. To do so, click Table Actions in the upper right corner of the results table. 

Select columns
The Select Columns screen in the Table Actions popup allows you to add or remove columns of motor data from the Results Table. 

Column order
The Column Order screen in the Table Actions popup allows you change the order in which the motor data columns are displayed. Simply drag and drop the columns into your preferred order.

Card view option
You can choose to view the motor data results as Cards. In the upper right corner of the results table, you will find two buttons: Table and Cards. Use these buttons to toggle between the two different view modes. (Click image to enlarge.)

From the list of filtered motor results, you may select one or more motors to open. Clicking a row selects that record. Multiple rows may be selected; or all rows may be selected by clicking the checkbox at the top left of the filtered motor results. When done selecting the motors to view, click View Motor Details at the top right of the table.

Each selected motor will be opened in the Motor Viewer with the motor's record number displayed as a tab at the top of the Motor Viewer.

A downloadable report can be generated for any motor currently open within the Motor Viewer. While that motor's details are displayed, click the Generate Report button in the upper right corner of the Motor Viewer.

In the popup, click Download to automatically generate the PDF and download it to your computer.

It is common to use data from a three phase winding from the EASA Motor Winding Database as the basis for a winding redesign. This is useful when original winding data is suspect or for bare core designs.

When a three phase winding from the EASA Winding Database is open in the Motor Viewer, the Send to Motor Editor button is available. It is located at the top right of the Motor Viewer.

Send to Motor Editor creates a new motor record in the Motor Editor and populates the fields with the data available from the winding database. The new redesign can then be calculated from that data instead of suspect or missing original data. Since many of the records in the EASA Motor Winding Database represent factory winding data, this is an excellent method for developing a redesign, especially for bare core situations.

Clicking "Create new motor" in the main navigation menu opens the Motor editor tool. Start with the required basic information: job number and motor manufacturer. The manufacturer is important data and to facilitate searching the manufacturer name must be spelled correctly. Motor Winding Workbench maintains a file of properly spelled manufacturer names. If the name you enter is not on the list, you must verify the name is spelled correctly (so it can be added to the list), or select "Unknown."

Optionally, you can also include frame, type, model, and number of leads. When done, click "Create motor" to open a new blank motor record.

This is the motor nameplate data section. Information entered in the create new motor popup appears here. You can also add additional details about the motor design, including:

• Frame prefix
• Frame base
• Frame suffix
• Type
• Model
• No. of leads
• RPM
• Additional notes about the motor

Winding Data
This is the motor winding nameplate data, and winding connection information, that is required to calculate the verification or redesign.

Certain combinations are invalid and will trigger an error message when Calculate is selected. An example is entering 6 poles with 4 circuits, since 4 circuits is not possible with a 6 pole winding.

Entering Concentric and Lap Coil Data
Either concentric or lap coil data can be entered. The data entry forms are different for the two types. Selecting the appropriate type will display the correct data entry form.

Lap Winding Coil Data Entry
Check consequent poles only if the original winding is such. A consequent pole winding will generally have half as many coil groups as a salient pole winding. For a consequent pole winding, the number of groups is equal to the number of poles x 3/2. An 8 pole, consequent pole winding would have 8 x 3/2 = 12 groups. An 8 pole, salient pole winding would have 24 groups.

Some lap windings have coils with two different turn counts. Select 1 or 2 for Number of Different Turns field. The corresponding number of data entry lines will be displayed. Also enter the Pitch and the Number of Coils for each data entry line.

Note: Any winding with more than one pitch would be entered as a concentric winding.

Concentric Winding Coil Data Entry
Check Consequent Pole only if the original winding is such. A consequent pole winding will generally have half as many coil groups as a salient pole winding. For a consequent pole winding, the number of groups is equal to the number of poles x 3/2. An 8 pole, consequent pole winding would have 8 x 3/2 = 12 groups. An 8 pole, salient pole winding would have 24 groups.

For concentric windings, enter the Total Number of Coils in Winding. The program will calculate the Coil-Grouping Combination, and display the corresponding number of coil data entry fields. As Turns and Pitch data is entered, the subsequent Pitch field will increment by 2, the most common pattern. The default pitch value can be overwritten to enter uncommon coil arrangements.

Wire data can be entered as AWG, metric, rectangular inch (RCIN), rectangular metric (RCMM), square inch (SQIN) or square metric (SQMM). Up to 5 different wire sizes can be specified, but all must be of the same type. For AWG and METRIC wire sizes, the wire size value can be entered directly or selected from a drop down list. In addition, the up and down cursor keys will scroll thought the available choices.

When SQUARE wire is selected, a single field is created to enter the dimension. The range of values is 1.00 mm to 20.00 mm, and 0.050 inches to 1.000 inches.

When RECTANGULAR wire is selected, two fields are created to enter the thickness and width of the wire. Values are entered as inches or millimeters with decimal values as necessary.

Entering Core Data
The core dimension data can be entered in either inches or millimeters. Also, the Tooth-Slot data can be entered as either the dimension of the tooth, or the dimension of the slot. The appropriate data fields will be active based on the tooth-slot selection.

The Back Iron Depth is the smallest dimension from the bottom of the slot to the outside of the core. If the outside of the core is not round, use the average dimension of the core.

Some cores have vent ducts which must be considered when calculating core densities. Enter the Number of Vent Ducts and the vent duct widths.

Redesign Data
The fields in the Redesign Data pane specify the parameters for the redesigned winding. Mark any appropriate checkboxes and enter the corresponding values.

Wire Type and Wire Size
Either AWG or metric wire sizes can be specified for the redesigned winding. If the check mark is removed from the Wire Type checkbox, the wire type for the redesigned winding will default to the Original Wire Type.

The Wire Sizes checkboxes allow the available wire sizes to be restricted. If the ½ Size checkbox is not marked, only whole number AWG sizes will be used for the redesigned winding. The ½ Size checkbox has no effect on metric wire sizes.

The Only Available checkbox enables the available wire selection which have been made in Settings > Set Available Wire Sizes. This allows a service center to select only wire sizes that are in stock. Note: The Wire Size Calculator, available after the redesigned winding has been calculated, will override the Available Wire Size selections, and allow any wire size to selected for the redesigned winding.

Round Turns
The redesign calculation will attempt to determine the number of turns necessary to match the original winding, with proportions applied for changes from the original to the specified redesign. The result of those calculations will be a decimal value. But Coil turns can only be integer values, so the calculated result is normally rounded to the closest integer value. When the calculated, rounded turns would produce a redesigned winding that is too strong or too weak, some coils may be wound with one more or one less turn to weaken or strengthen the redesigned winding. By marking the Round Turns – Half check box, the calculated turns are rounded to half integer (0.5) values. This makes selecting an appropriate connection easier, since greater precision data will be displayed in the selection grid.

To Lap – Verification Only
The program will only calculate salient pole, Lap winding redesigns. Core densities and current densities are also displayed with the redesign data. If display of only the Core and current densities is desired, select the Verification Only checkbox. Redesign data will not be displayed.

When valid data is entered and the Calculate button (located in the lower right) is clicked, the selection grid is displayed.

Using the Selection  Grid
The selection grid lists the possible redesign options that meet the tolerance set  Settings > Tolerances. The tolerance percentage is the comparison of the flux density produced by the original winding to the flux density that would result from the turns, pitch and connection of the options in the selection grid. The EASA default tolerance is set to 5%.

The grid columns can be sorted by clicking the column heading. The % column is the change in “effective turns” from the original. (Reducing effective turns increases flux density and power.) Sorting on the % column is helpful in selecting a Redesign that closely matches the original winding.

The values highlighted in  red  and  yellow  indicate values that exceed the tolerances in the settings. Above the table are options to filter the results by alarm condition and number of circuits.

One or several rows may be selected. The View Rewinds button will open each of the selections as a Bottom-Tab in the Motor Editor. The selection grid can be helpful in comparing possible redesign options, and further analysis of several options can be conducted in the Motor Editor.

On the original winding page (click the Top-Tab) the Calculate button or can be clicked to redisplay the selection grid and allow additional redesigns to be selected. Each additional selection from the selection grid will create a Bottom-Tab for that motor with the resulting redesign.

On the original data page, the top-center panel displays annotations, warnings and conditions that may require attention before a redesign is calculated. If the calculate button is not available, this panel will have information on what may be required to calculate a redesign.

On each redesign page (bottom-tab), a message panel at the bottom will list conditions that should be considered when choosing that redesign.

Data verification and redesign of machines with form coil windings can be done in Motor Winding Workbench with the exception of rectangular conductor and insulation dimensioning. To address this need, a Form Coil Worksheet has been added to EASA’s online calculators. 

GO TO THE CALCULATOR

This worksheet can be used as a standalone calculator, but the recommended practice is to use it in conjunction with Motor Winding Workbench. This process is represented in Figure 1.

Verify / Redesign Winding Data
EASA recommends performing verification and redesign activities for all stators being rewound in Motor Winding Workbench. Users should always remember that the program is just a calculator, and the user must understand the data they put in and the data that comes out. However, there are several tools available in the program to help minimize the chance of an error. Note that for the purposes of using the Form Coil Worksheet, we will calculate a lap redesign in Motor Winding Workbench even if no changes are being made. This allows access to several features not available when doing a verification. 

Generate Report → JSON Export
When viewing a redesign in Motor Winding Workbench, the Generate Report dropdown menu provides options for Winding Card, JSON export and Copy to clipboard. A JSON file is a text file that stores information in an organized way so different computer programs can easily read and share it. When you choose JSON export from the Generate Report dropdown menu, a file is written and downloaded to your device. The file name will be in the format “redesign-[easaMotorId]-[redesignId].json” where easaMotorID and redesignID are unique identifiers for the specific motor and redesign exported. 

Import Workbench (JSON file)
When logged in to easa.com, there are several ways to navigate to the online calculators. One way is to use the green support menu in the upper right. The Form Coil Worksheet is in the Winding Calculators section. The general layout of the worksheet is represented in Figure 2. If being used in conjunction with Motor Winding Workbench, the first step is to import the JSON file. This is done using the Import Workbench button at the top of the worksheet.

Dimension Form Coil
Once the JSON file is imported, you’ll notice several fields have been populated. The remaining input fields can be populated and updated in any order, but a reasonable approach is as follows. 

The “Job Number” section is just reference information and does not have to be completed to use the worksheet, but reference information can be entered as needed. Verify that the “Nameplate data” and “Winding data” sections are complete. 

The “Core dimensions” section should be complete on import with the exception of the “Finger plate” dimension, which is used for the axial extension of the pressure finger. 

The “Coil Dimensions” section will import the average coil extension from Workbench if it was entered. The “Extensions” values can be adjusted for differences between the lead end (LE) and opposite lead end (OLE), but this will have little effect on the output. To the right of the “Extensions,” calculated values will be displayed based on the voltage class and recommended spacing between coil end arms. Note that the calculated values will change based on other input parameters, so early calculations will not be accurate. The “Pin Diameters” are the inside diameters of the coil nose before insulation. There will also be calculated values for these based on voltage class and turn geometry, so early calculations may not be accurate. Also included in this section will be calculated estimates for some dimensions used in coil manufacturing including loop length, coil length, bottom and top straight section length, coil spread and coil pitch angle. 

The “Slot Fill” section will import slot dimensions entered in Workbench. The next step is to dimension the slot spacers or fillers. Recommended values will be calculated and displayed to the right of the input fields based on voltage class, but remember this is an iterative process, meaning you may have to revisit and adjust to develop a reasonable winding. After slot spacers are dimensioned, the insulation parameters should be entered. Some common options with typical dimensions are available to choose from, understanding that this is not an exhaustive list. Recommended values will be displayed to the right of the input field for several of the items but note that the recommended values may change as different options are selected. Ground insulation is entered using nominal mica tape thickness applied with a quantity of half-lapped (50% overlap) layers. If a “Check ground stress” message appears to the right of the “Mica Layers” input, the insulation build is thinner than recommended. 

The slot fill approach recommended here is an outside-in approach. That is, with the spacers and insulation dimensioned, the remaining slot space is allocated for copper. The “Strands High” and “Strands Wide” fields are for the cross section of the coil turn or wires in hand. The original conductor arrangement should not change without reason and proper evaluation. Once these two fields are populated, the calculated strand height and width will be displayed to the right of their input fields. Adjusting other input parameters will change the space remaining for sizing the conductor strand. Also, note that the calculated strand dimensions are average dimensions, understanding that multiple strands in height or width may have different dimensions. 

The “Other Calculations” section includes several calculated values that may be of interest for a form coil winding. There is a “Create Drawing” function in the bottom toolbar that will produce a scaled 2D dimensioned slot section and coil section drawing. This is a useful function for visualizing the slot fill. An example drawing is shown in Figure 3.

Print To PDF or Save JSON
The menu along the bottom allows the user to “Print” a file in hard copy, but most browsers support print to pdf as well. Additionally, the user can “Save” a JSON file that will contain all the inputs for the worksheet. The file name will be in the format “Form Coil Worksheet YYYY-MM-DD.json” and it can be renamed if desired. There is a “Load” function that allows the user to load a saved file back into the worksheet for additional work.

Once the redesign has been calculated, it is often necessary to adjust the wire sizes and the resulting slot fill, which also affects current density. 

Wire calculator
Each Redesign chooses wires based on a optimizing algorithm and the Original wire sizes. The algorithm seeks to match the Redesign slot fill to the Original slot fill. If a different wire selection is desired, perhaps because the slot is very tight or has extra room, the wire calculator allows selection of different wires and displays possible combinations along with the % difference from the target slot fill. The calculator displays the wire that were selected by the application and the Target area. Two wire sizes can be selected for evaluation and a different Target value may be entered if desired. Clicking the Recalculate button at the bottom will generate a list of possible wire combinations that are reasonable for the Redesign. Selecting a row and clicking Save will revise the Redesign wires to those selected and update the Current density value.

Report
Selecting Report displays a list of open redesigns for the active motor. One or several of the redesigns may be selected; a report will be created for each redesign selection.

The report uses the standard winding card format for the original data and for the redesign data. The report opens as a .pdf file in a separate browser window where it can be downloaded as a file or printed with the browser utilities.

Side-by-side
Opens a new screen in the Motor Editor with columns of data; one column for each open redesign. The display allows direct comparison of data for the various open redesigns.

Clone
The Clone function is designed for use when a stator has multiple windings. Since the nameplate and core dimension data is the same, Clone opens a new Original motor with that data; specific winding data can then be entered and redesigned. Cloned motors are linked to identify they are multiple windings in the same stator.

Clone should not be used to compare various Redesign options;  use the Selection Grid to choose various redesign options and compare them with the Side-by-Side feature.

Manual rewind
When the Selection Grid does not list suitable options for the desired Redesign, the Manual rewind option allows free-form entry of Circuits, Connection, Turns, Pitch and Amps. The Warning message advises that all Alarms, Warning and protections are bypassed when Manual rewind is used. The Create manual rewind button with add another Bottom-Tab with the resulting Redesign.

Click the save motor button located in the upper right corner to save the motor to your user's file storage. Members who have not purchased file storage are restricted to one saved redesign. Creating new Redesign will overwrite the stored Redesign. Members who have purchase file storage may store an unlimited number of motors.