Design of Experiments predictive models as a tool for lifespan prediction and comparison for enameled wires used in low voltage inverter-fed motors

Since the development of power electronic components, which allowed the manufacturing of reliable and efficient inverters, variable speed drives using inductive motors have become more and more popular. The PWM technique has proven to be a very effective method of rotational speed control. However, the fast changing voltage pulses, with very steep slopes (in the order of a few kV/μs), has brought new hazards for the electrical insulation system of such motors. Very high frequency harmonic components of PWM voltage will result in significant overvoltage due to an impedance mismatch between the cable and the motor. As an effect, the voltage seen by some parts of the insulation system may exceed the Partial Discharge Inception Voltage (PDIV) stating localized partial discharges activity. The aim of this paper is to investigate and analyze the aging process of the enameled wire exposed to different factors and to propose a method allowing to predict their lifespans in given conditions. This study introduces a prediction based on the Design of Experiments method and the statistical Weibull distribution. Thanks to the model obtained with short multi-stress aging tests, it is possible to predict the results of significantly longer ones. Moreover, the adapted methodology is proposed that allows to predict the scatter of the long tests basing on the short-time results dispersion. The same approach is used to compare different products between each other and rank them. All model predictions are compared with the experimental data in order to prove the model accuracy

Development of methods allowing the test and the comparison of low-voltage motors insulation systems running under partial discharges (fed by inverter)

Depuis le développement des composants d'électronique de puissance qui ont permis la fabrication d'onduleurs fiables et efficaces, les entraînements à vitesse variable utilisant des moteurs asynchrones sont devenus de plus en plus populaires. La technique MLI s'est avérée être une méthode très efficace de contrôle de la vitesse de rotation. Cependant, les impulsions de tension, avec des pentes très raides (de l'ordre de quelques kV/µs), ont apporté de nouveaux risques pour le système d'isolation électrique des moteurs. La richesse harmonique de la tension MLI entraînera une surtension significative due à une différence d'impédance entre le câble et le moteur. En effet, la tension observée par certaines parties du système d'isolation peut dépasser la tension d'apparition des décharges partielles (ang. PDIV); ce qui amorcera une activité de décharges partielles localisée. Le système d'isolation des machines basse tension (appelé type I) est basé presque entièrement sur des matériaux polymères qui ne sont pas conçus pour supporter des décharges partielles tout au long de leur vie. En raison de l'utilisation de variateurs de fréquence, l'isolation primaire du fil émaillée est en danger par rapport aux machines alimentées par réseau. En conséquence, c'est souvent le point le plus faible du système d'isolation qui conduira à la panne prématurée d'une machine. Le but de cette thèse est d'étudier et d'analyser le processus de vieillissement du fil émaillé exposé aux différents facteurs et de proposer une méthode permettant de prédire les durées de vie dans des conditions fixées. Cette étude introduit une prédiction basée sur la méthode des plans d'expériences et la distribution statistique de Weibull. Grâce au modèle obtenu avec des tests de vieillissement courts multicontraintes (température, tension, fréquence) il est possible de prédire les résultats de tests significativement plus longs. De plus, la méthodologie proposée permet de prédire la dispersion des essais longs en se basant sur la dispersion des résultats à court terme. Les prédictions sont comparées avec les données expérimentales afin de prouver la précision du modèle.Since the development of power electronic components, which allowed the manufacturing of reliable and efficient inverters, variable speed drives using inductive motors have become more and more popular. The PWM technique has proven to be a very effective method of rotational speed control. However, the fast changing voltage pulses, with very steep slopes (in the order of a few kV/µs), has brought new hazards for the electrical insulation system of such motors. Very high frequency harmonic components of PWM voltage will result in significant overvoltage due to an impedance mismatch between the cable and the motor. As an effect, the voltage seen by some parts of the insulation system may exceed the Partial Discharge Inception Voltage (PDIV) stating localized partial discharges activity. The insulation system in low-voltage machines (called type I) is based almost entirely on polymer materials, which are not able to support partial discharge activity throughout their lives. Due to the use of frequency inverters especially the primary insulation of the magnet wire is endangered in comparison with system-powered machines. As a result this is often the weakest link of the insulation system leading to a premature breakdown of the machine. The aim of this thesis is to investigate and analyze the aging process of the enameled wire exposed to different factors and to propose a method allowing to predict their lifespans in given conditions. This study introduces a prediction based on the Design of Experiments method and the statistical Weibull distribution. Thanks to the model obtained with short multi-stress (temperature, voltage, frequency) aging tests, it is possible to predict the results of significantly longer ones. Moreover, the adapted methodology is proposed that allows to predict the scatter of the long tests basing on the short-time results dispersion. The predictions are compared with the experimental data in order to prove the model accuracy

Design, taking into account the partial discharges phenomena, of the electrical insulation system (EIS) of high power electrical motors for hybrid electric propulsion of future regional aircrafts

La réduction des émissions de CO2 est un enjeu majeur pour l'Europe dans les années à venir. Les transports sont aujourd'hui à l'origine de 24% des émissions globales de CO2. L'aviation ne représente que 2% des émissions globales de CO2. Cependant, le trafic aérien est en pleine expansion et, déjà, des inquiétudes apparaissent. A titre d'exemple, en Suède, depuis les années 1990, les émissions de CO2 dues au trafic aérien ont augmenté de 61%. Ce constat explique l'apparition du mouvement "Flygskam" qui se repend dans de plus en plus de pays Européen. C'est dans ce contexte que l'Union Européenne a lancé en septembre 2016 le projet Hybrid Aircraft Academic research on Thermal and Electrical Components and Systems (HASTECS). Le consortium regroupe différents laboratoires et Airbus. Ce projet s'inscrit dans le programme "Clean Sky 2" qui vise à développer une aviation plus verte. L'objectif ambitieux est de réduire de 20% les émissions de CO2 et le bruit produits par les avions d'ici 2025. Pour cela, le consortium étudie une architecture hybride de type série. La propulsion est assurée par des moteurs électriques. Deux cibles ont été définies. En 2025, les moteurs doivent atteindre une densité de puissance de 5kW/kg, système de refroidissement inclus. En 2035, la densité de puissance des moteurs sera doublée pour atteindre 10kW/kg. Pour atteindre ces cibles, le niveau de tension sera considérablement augmenté, au-delà du kilovolt. Le risque de décharges électriques dans les stators des moteurs électriques est considérablement accru. L'objectif de cette thèse est de mettre au point un outil d'aide au design du Système d'Isolation Electrique (SIE) primaire du stator de moteur électrique piloté par convertisseur. Elle est découpée en cinq parties. La première partie commence par préciser les enjeux et défis d'une aviation plus verte. Le SIE du stator de moteur électrique est développé. Enfin, les contraintes qui s'appliquent sur le SIE dans l'environnement aéronautique sont identifiées. La deuxième partie présente les différents types de décharges électriques que l'on peut retrouver. Le principal risque vient des Décharges Partielles (DP) qui détériorent peu à peu le SIE. Le principal mécanisme pour expliquer l'apparition des DP est l'avalanche électronique. Le critère de Paschen permet d'évaluer le Seuil d'Apparition des Décharges Partielles (SADP). Différentes techniques permettent de détecter et mesurer l'activité des DP. Des modèles numériques permettent d'évaluer le SADP. La troisième partie présente une méthode originale pour déterminer les lignes de champ électrique dans un problème électrostatique. Elle n'utilise qu'une formulation en potentiel scalaire. La quatrième partie présente une étude expérimentale pour établir une correction du critère de Paschen. Un bobinage de moteur électrique est très loin des hypothèses dans lesquelles ce critère a été originellement défini. Enfin, la cinquième partie est consacrée à l'élaboration de l'outil d'aide au design du SIE. Des abaques sont construites afin de fournir des recommandations sur le dimensionnement des différents isolants dans une encoche de stator. Une réduction du SADP due à une variation combinée de la température et de la pression est prise en compte.Reducing CO2 emissions is a major challenge for Europe in the years to come. Nowadays, transport is the source of 24% of global CO2 emissions. Aviation accounts for only 2% of global CO2 emissions. However, air traffic is booming and concerns are emerging. For instance, CO2 emissions from air traffic have increased by 61% in Sweden since the 1990s. This explains the emergence of the "Flygskam" movement which is spreading in more and more European countries. It is in this context that the European Union launched in September 2016 the project Hybrid Aircraft Academic research on Thermal and Electrical Components and Systems (HASTECS). The consortium brings together different laboratories and Airbus. This project is part of the program "Clean Sky 2" which aims to develop a greener aviation. The ambitious goal is to reduce CO2 emissions and the noise produced by aircraft by 20% by 2025. To do that, the consortium is studying a serial hybrid architecture. Propulsion is provided by electric motors. Two targets are defined. In 2025, the engines must reach a power density of 5kW/kg, including the cooling system. In 2035, the power density of the engines will be doubled to reach 10kW/kg. To reach these targets, the voltage level will be considerably increased, beyond one kilovolt. The risk of electric discharges in the stators of electric motors is considerably increased. The objective of this thesis is to develop a tool to assist in the design of the primary Electrical Insulation System (EIS) of the stator of an electric motor controlled by a converter. It is organized in 5 parts. The first part begins by clarifying the issues and challenges of a greener aviation. The electric motor stator EIS is developed. Finally, the constraints that apply to the EIS in the aeronautical environment are identified. The second part presents the different types of electric discharges that can be found. The main risk comes from Partial Discharges (PD) which gradually deteriorate the EIS. The main mechanism for explaining the appearance of PD is the electronic avalanche. The Paschen criterion makes it possible to evaluate the Partial Discharge Inception Voltage (PDIV). Different techniques are used to detect and measure the activity of PD. Numerical models are used to evaluate the PDIV. The third part presents an original method for determining the electric field lines in an electrostatic problem. It only uses a scalar potential formulation. The fourth part presents an experimental study to establish a correction of the Paschen criterion. An electric motor winding is very far from the hypotheses in which this criterion was originally defined. Finally, the fifth part is devoted to the development of the SIE design aid tool. Graphs are generated to provide recommendations on the sizing of the various insulators in a stator slot. A reduction in the PDIV due to a combined variation in temperature and pressure is taken into account

HASTECS: Hybrid Aircraft: reSearch on Thermal and Electric Components and Systems

In 2019, transportation was the fastest growing sector, contributing to environmental degradation. Finding sustainable solutions that pollute less is a key element in solving this problem, particularly for the aviation sector, which accounts for around 2-3% of global CO2 emissions. With the advent of Covid-19, air traffic seems to have come to a fairly permanent halt, but this pandemic reinforces the need to move towards a "cleaner sky" and respect for the environment, which is the objective of the Clean Sky2 program (H2020 EU), the context in which the HASTECS project has been launched in September 2016

Methods for modeling degradation of electrical engineering components for lifetime prognosis

Reliability of electrical components is an issue studied to improve the quality of products, and to plan maintenance in case of failure. Reliability is measured by studying the causes of failure and the mean time to failure. One of the methods applied in this field is the study of component aging, because failure often occurs after degradation. The objective of this thesis is to model the degradation of components in electrical engineering, in order to estimate their lifetime. More specifically, this thesis will study large area organic white light sources (OLEDs). These sources offer several advantages in the world of lighting thanks to their thinness, their low energy consumption and their ability to adapt to a wide range of applications. The second components studied are electrical insulators applied to pairs of twisted copper wires, which are commonly used in low voltage electrical machines. First, the degradation and failure mechanisms of the various electrical components, including OLEDs and insulators, are studied. This is done to identify the operational stresses for including them in the aging model. After identifying the main causes of aging, general physical models are studied to quantify the effects of operational stresses. Empirical models are also presented when the physics of degradation is unknown or difficult to model. Next, methods for estimating the parameters of these models are presented, such as multilinear and nonlinear regression, as well as stochastic methods. Other methods based on artificial intelli­gence and online diagnosis are also presented, but they will not be studied in this thesis. These methods are applied to degradation data of organic LEDs and twisted pair insulators. For this purpose, accelerated and multifactor aging test benches are designed based on factorial experimental designs and response surface methods, in order to optimize the cost of the experiments. Then, a measurement protocol is described, in order to optimize the inspection time and to collect periodic data. Finally, estimation methods tackle unconstrained deterministic degradation models based on the measured data. The best empirical model of the degradation trajectory is then chosen based on model selection criteria. In a second step, the parameters of the degradation trajectories are modeled based on operational constraints. The parameters of the aging factors and their interactions are estimated by multilinear regression and according to different learning sets. The significance of the parameters is evaluated by statistical methods if possible. Finally, the lifetime of the experiments in the validation sets is predicted based on the parameters estimated by the different learning sets. The training set with the best lifetime prediction rate is considered the best

Proceedings of the 10th international conference on energy efficiency in motor driven systems (EEMODS' 2017)

The 10th International Conference on Energy Efficiency in Motor Driven Systems (EEMODS'17) was be held in Rome (Italy) on 6-8 September, 2017. The EEMODS conferences have been very successful in attracting distinguished and international presenters and attendees. The wide variety of stakeholders has included professionals involved in manufacturing, marketing, and promotion of energy efficient motors and motor driven systems and representatives from research labs, academia, and public policy. EEMODS’15 provided a forum to discuss and debate the latest developments in the impacts of electrical motor systems (advanced motors and drives, compressors, pumps, and fans) on energy and the environment, the policies and programmes adopted and planned, and the technical and commercial advances made in the dissemination and penetration of energy-efficient motor systems. In addition EEMODS covered also energy management in organizations, international harmonization of test method and financing of energy efficiency in motor systems. The Book of Proceedings contains the peer reviewed paper that have been presented at the conference.JRC.C.2-Energy Efficiency and Renewable