Thermal Overload and Insulation Aging of Short Duty Cycle, Aerospace Motors

Vincenzo Madonna, Paolo Giangrande, Luca Lusuardi, Andrea Cavallini, Chris Gerada, Michael Galea

Research output: Journal PublicationArticlepeer-review

77 Citations (Scopus)


Electrical machines for transportation applications need to be highly reliable, particularly if they drive safety-critical systems. At the same time, another main requirement is represented by the significant torque density, especially for aerospace, where weight constraints are extremely stringent. For achieving high peak torque, an effective strategy consists in supplying the windings with a current greater than the rated value; thus, thermally overloading the machine for limited time periods. However, if the insulation is overheated, the machine lifetime is shortened and reliability issues can arise. This paper experimentally investigates the influence of short-time thermal overload on the insulation lifetime for low voltage, random wound electrical machines. The analysis is performed on round enameled magnet wire coils, which are aged by accelerated thermal cycles. The obtained results are statistically processed through a two parameter Weibull distribution. According to the findings of the experimental data postprocessing, a lifetime prediction model is built. This model is employed for predicting the lifetime consumption of a motor embedded into an electromechanical actuator for aerospace application.

Original languageEnglish
Article number8709991
Pages (from-to)2618-2629
Number of pages12
JournalIEEE Transactions on Industrial Electronics
Issue number4
Publication statusPublished - Apr 2020


  • Accelerated lifetime testing
  • electromechanical actuators
  • insulation
  • lifetime model
  • more electric aircraft
  • permanent magnet synchronous machine (PMSM)
  • reliability

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Electrical and Electronic Engineering


Dive into the research topics of 'Thermal Overload and Insulation Aging of Short Duty Cycle, Aerospace Motors'. Together they form a unique fingerprint.

Cite this