Frequency Response Analysis for Quality Assurance Testing of Hairpin Stator Winding Insulation for Electric Vehicle Applications

IF 5 2区工程技术 Q2 ENERGY & FUELS

IEEE Transactions on Energy Conversion Pub Date : 2025-01-09 DOI:10.1109/TEC.2025.3527819

J. Kim;S. Shin;B. Battulga;M. F. Shaikh;Y. Park;C. Lim;S. B. Lee

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Abstract

With the rapid growth in electric vehicles (EV), hairpin wound stators are replacing random wound stators due to their higher power density and efficiency, and because of the ease with which manufacturing can be automated at a fast rate. Failure in the EV motor stator insulation is a major concern with increasing electrical stresses due to higher dc link voltage and wide bandgap devices. It is critical to implement a series of fast and effective quality assurance (QA) tests to screen defective units to maintain the quality and reliability, while keeping the production cost of EV motors low. Experience with EV motors showed that poor stator insulation quality is a leading cause of manufacturing defects in hairpin windings. In this work, the feasibility of applying frequency response analysis (FRA) for identifying defective hairpin stator insulation is evaluated. Test results on poorly impregnated EV motors with FRA and 6 common insulation tests show that FRA provides the most effective and reliable assessment of the insulation quality of hairpin wound stators.

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电动汽车用发夹定子绕组绝缘质量保证试验的频响分析

随着电动汽车（EV）的快速发展，发夹绕组定子由于其更高的功率密度和效率，以及易于快速自动化制造，正在取代随机绕组定子。由于更高的直流链路电压和宽带隙器件，EV电机定子绝缘故障是电气应力增加的主要问题。实施一系列快速有效的质量保证（QA）测试来筛选缺陷部件，以保持电动电机的质量和可靠性，同时降低生产成本，这是至关重要的。电动电机的经验表明，不良的定子绝缘质量是发夹绕组制造缺陷的主要原因。本文对频率响应分析（FRA）用于发夹定子绝缘缺陷识别的可行性进行了评价。采用FRA和6种常用绝缘试验对低浸渍EV电机进行的试验结果表明，FRA是评价发夹绕组定子绝缘质量最有效、最可靠的方法。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

IEEE Transactions on Energy Conversion 工程技术-工程：电子与电气

CiteScore

11.10

自引率

10.20%

发文量

230

审稿时长

4.2 months

期刊介绍： The IEEE Transactions on Energy Conversion includes in its venue the research, development, design, application, construction, installation, operation, analysis and control of electric power generating and energy storage equipment (along with conventional, cogeneration, nuclear, distributed or renewable sources, central station and grid connection). The scope also includes electromechanical energy conversion, electric machinery, devices, systems and facilities for the safe, reliable, and economic generation and utilization of electrical energy for general industrial, commercial, public, and domestic consumption of electrical energy.