Stator Housing with Pillars and Lid

1. Pillar Requirements and Spacing For a standard three-phase configuration with a high pole count (typically 12 coil positions for this scale), the calculations are as follows: Total Number of Pillars: 36 pillars [GeminiChat - Step 2]. This is derived from the "three-stick" innovation, where each of the 12 coil positions requires a skeletal triangle of 3 pillars to act as a bobbin [GeminiChat - Step 4, Point 2]. Angular Spacing: Each coil position is spaced exactly 30° apart (360° / 12 coils) [GeminiChat - Step 1]. Pillar Cross-Section: 3mm diameter vertical cylinders [GeminiChat - Step 2, Point 2]. 2. Coordinate Layout for One Coil (The Blueprint) In Onshape, it is easiest to model one set of 3 pillars and then use the Circular Pattern tool to replicate them 12 times. To maximize the space for your Litz wire and ensure the cooling fluid washes over the center, place the pillars at these relative coordinates within one 30° "wedge": Pillar Position Radius (r) Polar Angle (θ) Inner Pillar (P 1 ​ ) Inner Apex 25mm 15.0° (Center of the wedge) Outer Pillar (P 2 ​ ) Left Corner 55mm 2.5° (Offset from edge) Outer Pillar (P 3 ​ ) Right Corner 55mm 27.5° (Offset from edge) These radii ensure the pillars sit inside the trough walls (which are at 23mm and 57mm) with enough clearance for high-speed rotation and fluid flow [GeminiChat - Point 1, 2]. 3. Unified Stator "Solid Hollow Thing" Dimensions Following your idea for a solid hollow housing as seen in the images, here is the necessary data for your Onshape features: The Trough: Create a circular trench with a 2mm solid floor and 3mm thick walls [GeminiChat - Point 1]. Inner wall radius: 20mm (D in ​ /2). Outer wall radius: 60mm (D out ​ /2). Lid Sealing: Model a 1.5mm x 1.5mm rabbet joint along the top inner and outer perimeters of these walls to seat your lid for the isothermal MPCM slurry [GeminiChat - Point 4]. Mounting Lugs: Place 4 lugs at 90-degree intervals (0°, 90°, 180°, 270°) on the outer curved face. Each should be 10mm wide and 15mm high to match the lugs in your screenshot [GeminiChat - Point 3, 4]. Fluid Ports: Cut two 5mm holes at 0° and 180° through the outer wall. Placing them at opposite ends forces the fluid to split into semicircles, preventing the "dead zones" that cause thermal imbalance [GeminiChat - Point 5, 126].

Parameters

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