{
  "capturedAt": "2026-11-06T16:33:40.806Z",
  "route": "/learn/afpm-motor-design-for-manufacturing",
  "preset": "ev_traction",
  "modelVersion": "2026.11.06-dfm-v2",
  "image": "/images/learn/afpm-dfm-screening-software-evidence.webp",
  "width": 694,
  "height": 600,
  "sha256": "6cea7d416eb2503f0d13ee8e11d8f793fd2fcddb72f653312224ec194bbbc8b5",
  "originalSha256": "132a04adea59efcb7d479466927b5d0ffa7fe94a7dd59854cdbb85c63302830d",
  "captureScope": "Upper 600px of actual default result panel; crop and WebP encoding only. No hidden chrome or retouched results.",
  "inputs": {
    "outerDiameterMm": 260,
    "diameterRatio": 0.58,
    "airGapMm": 0.8,
    "ratedSpeedRpm": 7500,
    "polePairs": 10,
    "statorSlots": 12,
    "backIronThicknessMm": 10,
    "magnetThicknessMm": 6,
    "annualVolume": 5000,
    "topology": "yasa",
    "statorCoreType": "smc_segmented_teeth",
    "magnetRetention": "cfrp_sleeve"
  },
  "outputs": {
    "airGapFluxDensityT": 1.12,
    "activeAnnularAreaCm2": 352.3,
    "maxwellAttractiveForceKn": 17.58,
    "singleFaceForceGradientKnPerMm": 6.09,
    "discDeflectionMicrons": 29.5,
    "deflectionSafetyFactor": 27.1,
    "discBendingStatus": "rigid",
    "centrifugalTipSpeedMps": 102.1,
    "centrifugalHoopStressMpa": 79.2,
    "retentionAllowableStressMpa": null,
    "retentionSafetyFactor": null,
    "retentionStatus": "not_evaluated",
    "estimatedSlotFillFactorPct": 54,
    "windingProcessName": "CNC Segmented Tooth Bobbin Winding (Automated)",
    "windingAutomationLevel": "fully_automated",
    "toleranceStackup": {
      "rotorRunoutMicrons": 26,
      "bearingPlayMicrons": 30,
      "statorMountingMicrons": 32.5,
      "magnetThicknessMicrons": 20,
      "thermalDeltaMicrons": 26,
      "worstCaseTotalMicrons": 134.5,
      "rssTotalMicrons": 81.1,
      "airgapRssPercentage": 10.1,
      "status": "safe"
    },
    "remainingClearanceMicrons": 636,
    "dfmReadinessScore": 98,
    "readinessGrade": "Lower Modeled Concern — Unverified",
    "toolingCapexLevel": "High (SMC/Stamping Dies)",
    "assemblyMagneticHazardLevel": "Severe (Fixture Design Required)",
    "riskAlerts": [
      {
        "level": "warning",
        "title": "Magnet Retention Not Evaluated",
        "detail": "Tip speed and ρv² are demand indicators only. No selected retention method is verified by this tool.",
        "recommendation": "Obtain geometry-specific retention analysis, hot/aged material data and a guarded overspeed test plan before release."
      },
      {
        "level": "warning",
        "title": "High-Force Magnetic Assembly Precaution",
        "detail": "Illustrative single-face Maxwell attraction is 17.58 kN (1793 kgf). Uncontrolled manual assembly will cause pinch accidents or ceramic magnet chipping.",
        "recommendation": "Mandate non-magnetic (austenitic stainless / brass) guide posts and a calibrated jackscrew or hydraulic lead-in assembly fixture."
      }
    ]
  },
  "resultText": "HEURISTIC SCREENING SCORE\n98\n/ 100\nLower Modeled Concern — Unverified\nTooling heuristic (not a quote): High (SMC/Stamping Dies)\nAssembly Hazard: Severe (Fixture Design Required)\n\nMaxwell Force\n\n17.58 kN\n\nOne-face dF/dg: 6.1 kN/mm\n\nDisc Deflection\n\n29.5 µm\n\ng/δ: 27.1x\n\nInertial Stress Scale\n\n79.2 MPa\n\nCapacity: not evaluated\n\nSlot Fill Factor\n\n54%\n\nFixed planning placeholder\n\nDFM Alerts\nAirgap & Deflection\nStator & Winding DFM\nTolerance Stack-Up\nMANUFACTURING RISK ANALYSIS & MITIGATION CHECKPOINTS\n\nWARNING\nMagnet Retention Not Evaluated\n\nTip speed and ρv² are demand indicators only. No selected retention method is verified by this tool.\n\nAction: Obtain geometry-specific retention analysis, hot/aged material data and a guarded overspeed test plan before release.\n\nWARNING\nHigh-Force Magnetic Assembly Precaution\n\nIllustrative single-face Maxwell attraction is 17.58 kN (1793 kgf). Uncontrolled manual assembly will cause pinch accidents or ceramic magnet chipping.\n\nAction: Mandate non-magnetic (austenitic stainless / brass) guide posts and a calibrated jackscrew or hydraulic lead-in assembly fixture.\n\nIllustrative remaining clearance: 636 µm = gap − one-disc deflection − worst-case assumed stack. Two-disc closure and dynamic loads still require validation.\n\nNext: export this screen with drawings and request a geometry-specific review before tooling release.\n\nMethod, assumptions and score rules\nCopy DFM Brief for OEM RFQ\nDownload text brief\nDownload Engineering JSON\nRequest OEM DFM Tooling Review →\n\nEngineering Notice: Illustrative pre-tooling screen, not production approval. Uniform one-face magnetic pressure and an uncalibrated steel plate approximation omit hub geometry, rotor coupling, temperature-dependent properties, dynamics and structural load paths. Magnet retention capacity is unknown: geometry, material allowables, bond area, interference, ageing and overspeed tests are required. No output certifies safety, cost, yield or compliance.",
  "assumptions": "Fixed assumptions: Br = 1.3 T, recoil permeability = 1.05, full annular pole coverage; effective gap = 1.15g for iron cores or illustrative 1.8g for coreless designs (actual stator thickness not supplied); steel E = 205 GPa, ν = 0.3 and uncalibrated plate coefficient k = 0.125. Tolerance magnitudes are placeholders: rotor 20(D/200), bearing 30, mounting 25(D/200), magnet 20 and thermal closure 20(D/200), all in µm. RSS combines only mechanical magnitudes then adds thermal closure linearly; no distributions or sigma level are established. Pole/slot counts are recorded for RFQ only; winding compatibility and electromagnetic performance are not evaluated.",
  "disclaimer": "Illustrative pre-tooling screen, not production approval. Uniform one-face magnetic pressure and an uncalibrated steel plate approximation omit hub geometry, rotor coupling, temperature-dependent properties, dynamics and structural load paths. Magnet retention capacity is unknown: geometry, material allowables, bond area, interference, ageing and overspeed tests are required. No output certifies safety, cost, yield or compliance.",
  "evidenceBoundary": "Software execution only. No physical test, customer outcome, supplier capability or manufacturing approval."
}