Tight assembly of stator windings with no insulation paper damage is a manufacturing challenge. We evaluate different sets of parts according to the following parameters: magnet wire thickness, stator slot smoothness, length of the straight magnet wire after the slot end, and type and amount of insulation cap at the end of the slot. These parameters have discrete values with small differences between them. The damage criterion is the decrease of the insulation paper breakdown voltage after assembly/disassembly of parts, assembled in a small set of designed experiments. Parameter values, i.e., levels at individual experiments are set by an orthogonal experiment matrix. Repetition of each experiment provides statistical significance. Data analysis shows that the additive model alone is not sufficient due to the high correlation of the parameters' influences. We extend the model to include interparameter influences, which we model by adding a virtual parameter. The extended additive model generates parameter values that do not degrade the insulation paper breakdown voltage within the manufacturing process. These values are verified by repetitions of the control experiment. INDEX TERMS Analysis of variance, breakdown voltage, design for experiments, design for manufacture, dielectrics and electrical insulation, extended additive model, insulation paper damage, insulation testing, interparameter influence, in-wheel motor reliability, matrices, metal-insulator structures, orthogonal matrix experiments, permanent magnet motors, stators.

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