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Optimization of Insulation Structure Design for Enameled Wires Based on Molecular Structure Design.

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This study introduces a novel insulation structure for enameled wires in new energy vehicles, enhancing partial discharge inception voltage (PDIV) and corona voltage without compromising breakdown margin. The new design improves motor performance and power density.

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Area of Science:

  • Materials Science
  • Electrical Engineering
  • Polymer Science

Background:

  • Enameled wire performance is critical for new energy vehicle motors.
  • Current methods to improve partial discharge inception voltage (PDIV), such as powder doping and increased varnish thickness, have limitations including dispersion instability and reduced power density.

Purpose of the Study:

  • To design a novel insulation structure for enameled wires to enhance corona voltage and PDIV.
  • To control electronic field stress by utilizing materials with adjustable dielectric constants.
  • To improve the performance of enameled wires without negatively impacting their breakdown margin.

Main Methods:

  • A novel insulation structure was designed to control electronic field stress.
  • Dielectric constants were adjusted by modifying the free volume of the polymer.
  • A preparation scheme was developed to increase corona voltage and PDIV.

Main Results:

  • The outermost electric field strength of the enameled wire model decreased by 22.11%.
  • The enameled wire breakdown margin increased by 26.85%.
  • The new design successfully increased corona voltage and PDIV without compromising the breakdown margin.

Conclusions:

  • The novel insulation structure offers a superior alternative to conventional methods for enhancing enameled wire performance in electric motors.
  • Adjusting polymer free volume to control dielectric constants is an effective strategy for improving electrical insulation properties.
  • This advancement contributes to the development of more reliable and powerful new energy vehicle motors.