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Experimental modelling of stator poles for traction motors and influence of manufacturing defects

Ravanis Nikitas

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Summary

From its first concepts and commercial steps in the late 19th century, the internal combustion engine has been a driving force for human and cargo transportation around the world. However, today we are witnesses to a global shift when it comes to the automotive world as electric vehicles are getting more and more common. That is due to the several advantages of modern electric vehicles compared to their internal combustion brethren such as higher torque, efficiency, robustness, and most importantly enabling emission-free driving through the utilization of renewable energy. The Permanent Magnet Synchronous Motor(PMSM) is a special type of Synchronous Machine that utilises permanent magnets on its rotor instead of copper winding or bars. That results in a motor with excellent capabilities that offers significant advantages over traditional Synchronous Motors in terms of efficiency, size, reliability, and performance, making them increasingly popular in various industrial and commercial applications. However, due to their wide use range, permanent magnet motors can potentially be exposed to various stresses determined by their application. These stresses can gradually deteriorate motor insulation components over time, potentially leading to failure. Stator faults pose a significant risk in electric motors, as they can rapidly escalate into catastrophic breakdowns, and are directly connected with insulation system quality. This thesis aims to have PMSM poles undergo a variety of stresses and to use the produced degradation data to investigate the suitability of Frequency Response Analysis (FRA) as a quality assessment tool for PMSM pole insulation systems. To accomplish that, first a comprehensive equivalent circuit model for PMSM stator poles and their mounted armature coils, in their respective healthy state, will be showcased. The parameters of the aforementioned model are extracted from experimental results from various tests carried out on healthy poles. Analysis of the model will give us insight on the behaviour of the Frequency Response Analysis graphs when model parameters change in value. Finally, we will test the reliability of Frequency Response Analysis as a quality assessment tool by selecting poles that show weakness in the insulation system originating from their healthy state data and poles that exhibit a strong insulation system, and comparing their insulation degradation process during the accelerated ageing cycles with the ultimate goal of evaluating the reliability of FRA as a quality assessment technique to discern defective poles from the final motor assembly.

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