The Insulation Resilience of Inverter-Fed Low Voltage Traction Machines: Review, Challenges, and Opportunities

Abstract

The use of wide bandgap (WBG) semiconductor devices, which enable higher switching slew rates, and the increase in DC link voltage, which provides system-wide advantages, exposes the winding system of traction machines to enhanced electrical stress. The resulting nonlinear voltage distribution along the motor winding favors partial discharges (PD), which in low voltage (LV) machines causes excessive damage to the insulation system, and premature failure can occur. A simple solution by increasing the enamel thickness of the wires leads on the one hand to a lower copper fill factor. On the other hand, this measure is not necessarily accompanied by an increase in electrical resilience in the case of pulsed voltage. It is therefore essential to understand the phenomenon of partial discharges, which is composed of a large number of processes and mechanisms, to be able to make an estimation of aging. The ultimate goal is to derive a lifetime model that links the dynamic load collectives -ideally in conjunction with the environmental stress influences -of a traction application to a usage-dependent and realistic prediction of the residual lifetime. To this end, this paper provides an overview of the current state of science and technology in this interdisciplinary topic by describing, with reference to high voltage (HV) technology/engineering, the design of the insulation system, the discharge physics, the degradation mechanisms, the statistical effects to be considered, and the partial discharge measurement methods.

A Review of Power Electronic Devices for Heavy Goods Vehicles Electrification: Performance and Reliability

“…Upcoming challenges: This review has characterised the main power device technologies suitable for HGV applications. Nevertheless, considering the converter implementation, other challenges include EMI/EMC [93][94][95], investigating the impact of high voltage commutation rates on motor insulation reliability [96][97][98], power module/converter designs involving multiple chips in parallel and optimised busbars [99][100][101], thermal management and increased power densities [102,103], short circuit detection [104,105] and application-specific qualification methodologies/guidelines, as suggested by the JEDEC JC-70 guidelines and the ECPE guidelines for the qualification of power modules used in motor vehicles (AQG 324) [106]. The increased commercial availability of higher voltage devices (1.7 kV to 3.3 kV rated) may open new avenues for higher voltage charger designs and even higher inverter bus voltages.…”

A Pareto Based Comparison of DC/DC Converters for Variable DC-Link Voltage in Electric Vehicles

“…A higher voltage also poses challenges in the design of electrical components and systems. Higher voltages imply higher stress on the passive components and the winding insulations of the iPMSM [3]- [7], or a higher cosmic ray failure rate of the semiconductors [8], [9], which can lead to a reduced lifetime of the components. Moreover, the high battery voltage, and thus the DC-Link voltage, leads to disadvantages during the operation of the electric drive.…”