The Insulation Resilience of Inverter-Fed Low Voltage Traction Machines: Review, Challenges, and Opportunities

Abstract

The use of wide bandgap (WBG) semiconductor devices, which enable higher switching slew rates, and the increase in DC link voltage, which provides system-wide advantages, exposes the winding system of traction machines to enhanced electrical stress. The resulting nonlinear voltage distribution along the motor winding favors partial discharges (PD), which in low voltage (LV) machines causes excessive damage to the insulation system, and premature failure can occur. A simple solution by increasing the enamel thickness of the wires leads on the one hand to a lower copper fill factor. On the other hand, this measure is not necessarily accompanied by an increase in electrical resilience in the case of pulsed voltage. It is therefore essential to understand the phenomenon of partial discharges, which is composed of a large number of processes and mechanisms, to be able to make an estimation of aging. The ultimate goal is to derive a lifetime model that links the dynamic load collectives – ideally in conjunction with the environmental stress influences – of a traction application to a usage-dependent and realistic prediction of the residual lifetime. To this end, this paper provides an overview of the current state of science and technology in this interdisciplinary topic by describing, with reference to high voltage (HV) technology/engineering, the design of the insulation system, the discharge physics, the degradation mechanisms, the statistical effects to be considered, and the partial discharge measurement methods.

Keywords

• Accelerated aging
• automotive
• electrical machine
• electrical stress
• hairpin
• insulation degradation