Introducing physics of failure considerations in the electrical machines design

Vincenzo Madonna, Paolo Giangrande, Michael Galea

Research output: Chapter in Book/Conference proceedingConference contributionpeer-review

18 Citations (Scopus)

Abstract

For continuous-duty applications, electric motors are conventionally designed to experience a hot-spot temperature below their insulation thermal class. When frequent overloads are required, a safety temperature-margin is considered at the machine's design stage, so that the insulation is not thermally overstressed. This procedure leads to an increment of the machine's size, with a consequent power density reduction. Indeed, lower thermal loadings are obtained by decreasing the winding current density by e.g. increasing the equivalent cross-sectional area of conductors. For some applications, it is possible to avoid the 'over-engineering', but the reliability level might be compromised. This work addresses the subject of thermal overload capability in electrical machines, combining elements of thermal analysis, reliability and physics of failure. A novel design methodology is introduced and validated by means of thermal accelerated lifetime tests on winding specimens. The proposed approach is used for redesigning a brushless DC motor achieving excellent results in terms of power density boost.

Original languageEnglish
Title of host publication2019 IEEE International Electric Machines and Drives Conference, IEMDC 2019
PublisherInstitute of Electrical and Electronics Engineers Inc.
Pages2233-2238
Number of pages6
ISBN (Electronic)9781538693490
DOIs
Publication statusPublished - May 2019
Event11th IEEE International Electric Machines and Drives Conference, IEMDC 2019 - San Diego, United States
Duration: 12 May 201915 May 2019

Publication series

Name2019 IEEE International Electric Machines and Drives Conference, IEMDC 2019

Conference

Conference11th IEEE International Electric Machines and Drives Conference, IEMDC 2019
Country/TerritoryUnited States
CitySan Diego
Period12/05/1915/05/19

Keywords

  • Accelerated aging tests
  • Bldc
  • Insulating materials
  • Organic insulation
  • Physics of failure
  • Thermal analysis
  • Uav

ASJC Scopus subject areas

  • Energy Engineering and Power Technology
  • Electrical and Electronic Engineering
  • Mechanical Engineering

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