Moving Toward a Reliability-Oriented Design Approach of Low-Voltage Electrical Machines by Including Insulation Thermal Aging Considerations

Paolo Giangrande, Vincenzo Madonna, Stefano Nuzzo, Michael Galea

Research output: Journal PublicationArticlepeer-review

28 Citations (Scopus)

Abstract

Electrical machines (EMs) are required to consistently perform their intended mission over a specified timeframe. The move toward transportation electrification made the EMs' reliability an even stringent and predominant requirement, since a failure might cause severe economic losses, as well as endanger human lives. Traditionally, the design procedure of motors conceived for safety-critical applications mainly relies on over-engineering approaches. However, a paradigm shift is recently taking place and physics of failure approaches/methodologies are employed to meet the reliability figures, while delivering an optimal design. This article proposes and outlines a reliability-oriented design for low-voltage EMs. Thermal accelerated aging tests are preliminarily carried out on custom-built specimens. Once the aging trend of the turn-to-turn insulation system is assessed, the thermal endurance graph at several percentile values is determined and lifetime models are developed, for both constant and variable temperature operations. Finally, these models are used to predict the turn-to-turn insulation lifetime of motors meant for aerospace and automotive applications.

Original languageEnglish
Article number8978960
Pages (from-to)16-27
Number of pages12
JournalIEEE Transactions on Transportation Electrification
Volume6
Issue number1
DOIs
Publication statusPublished - Mar 2020

Keywords

  • Accelerated thermal aging tests
  • design of experiments
  • dielectric breakdown
  • electrical machines (EMs) insulation
  • physics of failure (PoF)

ASJC Scopus subject areas

  • Automotive Engineering
  • Transportation
  • Energy Engineering and Power Technology
  • Electrical and Electronic Engineering

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