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Title: Resistively Graded Insulation System for Next-Generation Converter-Fed Motors

Abstract

The objective of this project was to demonstrate the feasibility of a new insulation material system capable of withstanding 10 kV/μs switching voltage ramp rate (dV/dt) with operating frequencies and temperatures targeted at converter-fed motors. If successful, with additional development, this insulation material can enable 5%-10% electric machine energy savings from advanced silicon carbide (SiC) drive implementation. To accomplish these goals, we propose to eliminate partial discharge as a degradation mechanism in high voltage, taped insulation. This can be accomplished through the use of a two-sided coating on a polymer film system that will envelop any residual defects on all sides, effectively creating a Faraday cage around the defect. This project focused on demonstrating the proof of concept for the coating. It was shown that concept of providing a stress grading coating around voids can prevent partial discharge. Simulation and lab scale experiments showed that the design can be implemented in a practical layered structure without causing overheating of the insulation due to conduction. Short term testing and calculations show there is a reasonable likelihood to improved insulation life. A path to full scale production was demonstrated, with gaps in process optimization identified as needing to be closed for fullmore » scale implementation. Longer term testing and integration onto a conductor is required to fully quantify life and show benefits at an application level.« less

Authors:
 [1];  [1];  [1];  [1]
  1. General Electric, Global Research Center, Niskayuna, NY (United States)
Publication Date:
Research Org.:
General Electric, Global Research Center, Niskayuna, NY (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A)
OSTI Identifier:
1483295
Report Number(s):
DOE-GEGRC-0007873
DOE Contract Number:  
EE0007873
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; 33 ADVANCED PROPULSION SYSTEMS; 36 MATERIALS SCIENCE; electrical insulation; medium voltage; motors

Citation Formats

Calebrese, Christopher, Smith, David, Zhang, Lili, and Zhong, Wesley. Resistively Graded Insulation System for Next-Generation Converter-Fed Motors. United States: N. p., 2018. Web. doi:10.2172/1483295.
Calebrese, Christopher, Smith, David, Zhang, Lili, & Zhong, Wesley. Resistively Graded Insulation System for Next-Generation Converter-Fed Motors. United States. doi:10.2172/1483295.
Calebrese, Christopher, Smith, David, Zhang, Lili, and Zhong, Wesley. Tue . "Resistively Graded Insulation System for Next-Generation Converter-Fed Motors". United States. doi:10.2172/1483295. https://www.osti.gov/servlets/purl/1483295.
@article{osti_1483295,
title = {Resistively Graded Insulation System for Next-Generation Converter-Fed Motors},
author = {Calebrese, Christopher and Smith, David and Zhang, Lili and Zhong, Wesley},
abstractNote = {The objective of this project was to demonstrate the feasibility of a new insulation material system capable of withstanding 10 kV/μs switching voltage ramp rate (dV/dt) with operating frequencies and temperatures targeted at converter-fed motors. If successful, with additional development, this insulation material can enable 5%-10% electric machine energy savings from advanced silicon carbide (SiC) drive implementation. To accomplish these goals, we propose to eliminate partial discharge as a degradation mechanism in high voltage, taped insulation. This can be accomplished through the use of a two-sided coating on a polymer film system that will envelop any residual defects on all sides, effectively creating a Faraday cage around the defect. This project focused on demonstrating the proof of concept for the coating. It was shown that concept of providing a stress grading coating around voids can prevent partial discharge. Simulation and lab scale experiments showed that the design can be implemented in a practical layered structure without causing overheating of the insulation due to conduction. Short term testing and calculations show there is a reasonable likelihood to improved insulation life. A path to full scale production was demonstrated, with gaps in process optimization identified as needing to be closed for full scale implementation. Longer term testing and integration onto a conductor is required to fully quantify life and show benefits at an application level.},
doi = {10.2172/1483295},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2018},
month = {10}
}