Abstract: Aspects of the present disclosure are directed to systems and methods for detecting Partial Discharge (PD) associated with wide bandgap semiconductor-based electrical drive systems in real time. In one aspect, signals, including noise associated with drive switching and other background noises are detected using a sensing device. The signals are received by a real-time spectrum analyzer. The spectrum analyzer transforms the signals into the frequency domain and determines or registers the frequency domain profiles of the signals. The spectrum analyzer performs signal discrimination between at least one other signal included within the signals and switching noise based on their frequency domain profiles. Based on the discrimination analysis, the presence of a partial discharge signal may be detected. A physics-based signal discrimination approach can also be used for signal discrimination, for example utilizing pressure-dependency of characteristics of a PD signal.

Abstract: Aspects of the present disclosure are directed to systems and methods for detecting Partial Discharge (PD) associated with wide bandgap semiconductor-based electrical drive systems in real time. In one aspect, signals, including noise associated with drive switching and other background noises are detected using a sensing device. The signals are received by a real-time spectrum analyzer. The spectrum analyzer transforms the signals into the frequency domain and determines or registers the frequency domain profiles of the signals. The spectrum analyzer performs signal discrimination between at least one other signal included within the signals and switching noise based on their frequency domain profiles. Based on the discrimination analysis, the presence of a partial discharge signal may be detected. A physics-based signal discrimination approach can also be used for signal discrimination, for example utilizing pressure-dependency of characteristics of a PD signal.

Abstract: A method includes forming one or more cores, wherein each of the one or more cores has a cross section corresponding to a conductor to be subsequently formed, forming an insulator around the one or more cores, removing the one or more cores to expose one or more recesses within the insulator, and forming one or more conductors in at least one of the one or more recesses of the insulator such that the cross sections of the one or more conductors conform to an interior surface of the one or more recesses in the insulator.

Abstract: An electrical machine of a vehicle electrical propulsion system includes a stator, a rotor, and a stator winding all disposed within a housing thereof. The stator defines a central bore elongated along a longitudinal axis, and multiple slots circumferentially disposed around the central bore. The rotor is held within the central bore and rotates relative to the stator. The stator winding includes a core conductor, an insulation layer surrounding the core conductor, and a conductive shield layer surrounding the insulation layer. The stator winding extends through the slots of the stator. The stator winding includes an in-slot portion within the slots of the stator and an end-winding portion outside of the slots. The conductive shield layer surrounds the insulation layer along both the in-slot portion and the end-winding portion of the stator winding.

Abstract: An electrical insulating system and an associated insulated stator bar are provided. The electrical insulating system includes an electrically insulating mica paper and a fiber glass disposed on a first surface of the electrically insulating mica paper. The electrically insulating mica paper and the fiber glass are impregnated with a curable binder resin composition. The curable binder resin composition includes about 21 weight percent to about 73 weight percent of a solid or semi-solid epoxy resin having an epoxide functionality of about 2.5, about 0.8 weight percent to about 49 weight percent of a liquid epoxy resin having an epoxide functionality of about 2, about 4 weight percent to about 15 weight percent of a bisphenol A-formaldehyde novolac, a metal acetylacetonate catalyst, and about 2.5 weight percent to about 15 weight percent of a toughener selected from the group consisting of polyethersulfone, methylmethacrylate butadiene styrene, and a combination thereof.

Abstract: A method includes forming one or more cores, wherein each of the one or more cores has a cross section corresponding to a conductor to be subsequently formed, forming an insulator around the one or more cores, removing the one or more cores to expose one or more recesses within the insulator, and forming one or more conductors in at least one of the one or more recesses of the insulator such that the cross sections of the one or more conductors conform to an interior surface of the one or more recesses in the insulator.

Abstract: A method includes forming one or more cores, wherein each of the one or more cores has a cross section corresponding to a conductor to be subsequently formed, forming an insulator around the one or more cores, removing the one or more cores to expose one or more recesses within the insulator, and forming one or more conductors in at least one of the one or more recesses of the insulator such that the cross sections of the one or more conductors conform to an interior surface of the one or more recesses in the insulator.

Abstract: A method for forming an article is presented. The method includes providing one or more ceramic insulators having one or more recesses, providing a plurality of conductors within the one or more recesses of the one or more ceramic insulators, and joining a first conductor of the plurality of conductors to a second conductor of the plurality of conductors.

Abstract: Insulation systems that present an electrical stress grading through the disposition of resistively graded networks between insulating layers is described. The resistively graded networks may be implemented by coating insulating material with resistive material, and wrapping the insulation material around a conductor. The resistive material may be linear or non-linear material. Fabrication of the insulating material, the resistive material, and the coating process are also discussed, as well as the application of the insulation to the conductor are also discussed.

Abstract: An electrical machine of a vehicle electrical propulsion system includes a stator, a rotor, and a stator winding all disposed within a housing thereof. The stator defines a central bore elongated along a longitudinal axis, and multiple slots circumferentially disposed around the central bore. The rotor is held within the central bore and rotates relative to the stator. The stator winding includes a core conductor, an insulation layer surrounding the core conductor, and a conductive shield layer surrounding the insulation layer. The stator winding extends through the slots of the stator. The stator winding includes an in-slot portion within the slots of the stator and an end-winding portion outside of the slots. The conductive shield layer surrounds the insulation layer along both the in-slot portion and the end-winding portion of the stator winding.

Abstract: Insulation systems that present an electrical stress grading through the disposition of resistively graded networks between insulating layers is described. The resistively graded networks may be implemented by coating insulating material with resistive material, and wrapping the insulation material around a conductor. The resistive material may be linear or non-linear material. Fabrication of the insulating material, the resistive material, and the coating process are also discussed, as well as the application of the insulation to the conductor are also discussed.

Abstract: A method includes forming one or more cores, wherein each of the one or more cores has a cross section corresponding to a conductor to be subsequently formed, forming an insulator around the one or more cores, removing the one or more cores to expose one or more recesses within the insulator, and forming one or more conductors in at least one of the one or more recesses of the insulator such that the cross sections of the one or more conductors conform to an interior surface of the one or more recesses in the insulator.

Abstract: An electrical insulating system and an associated insulated stator bar are provided. The electrical insulating system includes an electrically insulating mica paper and a fiber glass disposed on a first surface of the electrically insulating mica paper. The electrically insulating mica paper and the fiber glass are impregnated with a curable binder resin composition. The curable binder resin composition includes about 21 weight percent to about 73 weight percent of a solid or semi-solid epoxy resin having an epoxide functionality of about 2.5, about 0.8 weight percent to about 49 weight percent of a liquid epoxy resin having an epoxide functionality of about 2, about 4 weight percent to about 15 weight percent of a bisphenol A-formaldehyde novolac, a metal acetylacetonate catalyst, and about 2.5 weight percent to about 15 weight percent of a toughener selected from the group consisting of polyethersulfone, methylmethacrylate butadiene styrene, and a combination thereof.

Abstract: A method for improving the electric field distribution in a high voltage direct current cable includes providing a cable that includes a conductor, a protective jacket, a shield layer disposed inside the jacket, and an insulation layer disposed inside the shield layer, surrounding the conductor. The insulation layer includes ethylene-propylene rubber, talc, and montmorillonite.

Abstract: Embodiments of an insulation for electrical components are provided herein. In one embodiment an insulation for an electrical component may include a filler dispersed throughout a polymer matrix, the filler comprising a talc containing nanoclay and boron nitride. In one embodiment, an insulating tape for an electrical component may include a substrate and an insulation disposed atop the substrate, the insulation comprising a filler dispersed throughout a polymer matrix, the filler comprising a talc containing nanoclay and boron nitride. In one embodiment, a stator bar may include a conductive core and an insulating tape disposed atop one or more surfaces of the conductive core, the insulating tape comprising a substrate and an insulation disposed atop the substrate, the insulation comprising a filler dispersed throughout a polymer matrix, the filler comprising a talc containing nanoclay and boron nitride.