Condition Monitoring Sensor for Electric Vehicle Motor and Generator Insulation Systems

Electric vehicle (EV) motors are subject to extreme and variable loads, resulting in degradation of winding insulation due to high temperatures. This paper describes research on a new conductive composite sensor, which uses insulation resin as a matrix of the sensor element. The sensor, embedded in the windings of EV motors, will provide data on remaining design life of the insulation based on actual vehicle operational and environmental conditions. Improved condition monitoring of the insulation systems of high-performance EV motors can reduce in-use failures by identifying prematurely degraded insulation systems, and providing data for quality improvement programs.