Insulation for Rotating Low-Voltage Electrical Machines: Degradation, Lifetime Modeling, and Accelerated Aging Tests
Abstract
:1. Introduction
2. EM Development and Insulation System
2.1. EM Modern Applications
2.2. Winding and Insulation System
- The enameled round wires (i.e., round copper conductors insulated by the organic insulation) ensure the insulation among turns, and turn-to-turn insulation breakdown might quickly escalate to more severe failures [53]. For this reason, several investigations are focused on the dielectric behavior of inter-turn insulation [11,54,55];
- The phase-to-phase insulation consists of an insulation paper sheet, which is located between the phase’s coils, increasing the dielectric strength [56]. Phase separators are also placed in the end winding region [57,58], where the probability of failure occurrence is higher. Common insulation papers are made of aramid (i.e., Nomex in Dupont trade), polyester film (Mylar), or polyester fleece (Dacron) [52];
- The phase-to-ground insulation also employs insulation paper, namely slot liner, to prevent contact between coils and the stator core. The slot liner’s thickness depends on the voltage class of EMs [59], and a possible failure triggers an asymmetric fault.
3. EM Development and Insulation System
3.1. Thermal Stress and Aging
3.2. Electrical Stress and PD
3.3. Ambient Stress
3.4. Mechanical Stress
4. Insulation Lifetime Modelling
4.1. Thermal Lifetime Models
4.1.1. Thermal Lifetime Modelling at Constant Temperature
4.1.2. Thermal Lifetime Modelling at Variable Temperature
- application mission profile;
- windings temperature profile;
- lifetime model parameters obtained through ALT.
4.2. Electric Stress Lifetime Modelling
4.3. Lifetime Modelling under Thermo-Electrical Stress
4.3.1. Simoni’s Model
4.3.2. Fallou’s Model
4.3.3. Ramu’s Model
4.4. Lifetime Modelling under Thermo-Electrical Stress
4.4.1. Thermal-Induced Mechanical Stress Model
4.4.2. Thermal-Induced Mechanical Stress Model
4.5. Summary of Insulation Lifetime Models
5. Accelerate Lifetime Tests
5.1. Thermal ALT at Constant Temperature
5.1.1. Experimental Setup
5.1.2. Specimens’ Choice
5.1.3. Diagnostic Session
5.2. Thermal ALT at Variable Temperature
5.2.1. Experimental Setup
5.2.2. Specimens’ Choice
5.3. Electrical Endurance and PD Tests
5.3.1. Experimental Platform Setup for Electrical Aging
5.3.2. Specimens’ Choice
6. Reliability Oriented Design and Remaining Useful Life
7. Conclusions and Future Perspectives
Funding
Data Availability Statement
Conflicts of Interest
Abbreviation
AEA | All Electric Aircraft |
ALT | Accelerated Lifetime Test |
EM | Electric Machine |
EV | Electric Vehicle |
EIS | Electric Insulation System |
ELM | Exponential Law Model |
eVTOL | electrical Vertical Take-Off and Landing aircraft |
FEA | Finite Element Analysis |
HV | High Voltage |
IEC | International Electrotechnical Commission |
IPM | Inverse Power Law Model |
LV | Low Voltage |
MEA | More Electric Aircraft |
OF | Overvoltage Factor |
PAI | Polyamideimide |
PD | Partial Discharge |
PDIV | Partial Discharge Inception Voltage |
PEI | Polyetherimide |
PMT | Photomultiplier Tube |
PoF | Physics of Failure |
RoD | Reliability-oriented Design |
PWM | Pulse Width Modulation |
RUL | Remaining Useful Life |
TEAM | Thermal, Electrical, Ambient, Mechanical |
Tg | Transition to Glass |
TP | Temperature Profile |
TEC | Thermal Expansion Coefficient |
VEC | Voltage-Endurance Coefficient |
VSD | Variable Speed Drive |
WBG | Wide Bandgap |
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Components | HV EM | LV EM |
---|---|---|
Stator Insulation Failure | 66% | 36% |
Rotor Failure | 13% | 9% |
Bearing | 13% | 41% |
Other | 8% | 14% |
Components | Turn to Turn | Phase to Phase | Phase to Ground | All the EM | |
---|---|---|---|---|---|
Name | enameled wires | slot separator | slot liner | slot wedge | resin and varnishes |
Materials | PAI, PEI, Polyvinyl Chloride. etc. | Aramid paper (i.e., Nomex in Dupont trade), polyester film (Mylar), or polyester fleece (Dacron) | Same as slot separator tapes | Rigid laminates and molded parts; pre-preg and B-stage | Polyesters, epoxies, and polyesterimides (liquids) |
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Zhou, X.; Giangrande, P.; Ji, Y.; Zhao, W.; Ijaz, S.; Galea, M. Insulation for Rotating Low-Voltage Electrical Machines: Degradation, Lifetime Modeling, and Accelerated Aging Tests. Energies 2024, 17, 1987. https://doi.org/10.3390/en17091987
Zhou X, Giangrande P, Ji Y, Zhao W, Ijaz S, Galea M. Insulation for Rotating Low-Voltage Electrical Machines: Degradation, Lifetime Modeling, and Accelerated Aging Tests. Energies. 2024; 17(9):1987. https://doi.org/10.3390/en17091987
Chicago/Turabian StyleZhou, Xuanming, Paolo Giangrande, Yatai Ji, Weiduo Zhao, Salman Ijaz, and Michael Galea. 2024. "Insulation for Rotating Low-Voltage Electrical Machines: Degradation, Lifetime Modeling, and Accelerated Aging Tests" Energies 17, no. 9: 1987. https://doi.org/10.3390/en17091987