Stator Winding Shielding for High-Voltage Partial Discharge Control
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Solution Overview
Problem
Current stator windings in electric machines are limited by electrical characteristic thresholds, particularly at high altitudes, leading to inefficiencies and increased risk of partial discharges due to insulation layer thickness requirements, which restrict voltage and current levels and reduce power output.
Innovation Solution
The implementation of a stator winding assembly with a conductor core, insulation layer, and conductive shield layer, where the conductive shield layer is conductively connected to a terminal end and acts as a common ground, along with a semi-conductive layer to manage local electric fields, preventing partial discharges and allowing for higher voltage operation without increasing overall thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulation layer thickness is increased to prevent partial discharges at high voltages and altitudes, then the electrical reliability is improved, but the power density and operational efficiency deteriorate due to increased overall thickness
Solution Approach 1:
The insulation system is segmented into multiple functional layers: a base insulation layer for primary electrical isolation, a semi-conductive layer for field management, and a conductive shield layer for discharge prevention. This segmentation allows each layer to be optimized for its specific function rather than requiring a single thick insulation layer, thereby maintaining power density while improving electrical reliability.
Solution Approach 2:
The semi-conductive layer acts as an intermediary between the conductive shield layer and the base insulation layer. It manages the electric field distribution and prevents field concentration at interfaces, enabling the system to operate at higher voltages without requiring excessive insulation thickness, thus resolving the contradiction between reliability and power density.
2Reliability
If the insulation layer thickness is increased to prevent partial discharges, then the risk of partial discharges is reduced, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The insulation structure is divided into distinct functional layers with clear interfaces. The base insulation layer provides primary isolation, the semi-conductive layer manages electric fields, and the conductive shield layer prevents discharges. This segmentation simplifies manufacturing by allowing each layer to be applied independently with standardized procedures, reducing overall complexity despite the multi-layer structure.
Solution Approach 2:
The invention changes the electrical parameters of the insulation system by introducing layers with different conductivity characteristics. The semi-conductive layer has intermediate conductivity, and the conductive shield layer has high conductivity. This parameter variation enables effective partial discharge prevention through controlled electric field distribution rather than relying solely on increased thickness, thereby simplifying the overall structure.
3Power
If the voltage and current levels are increased to improve power output, then the power density is improved, but the risk of partial discharges and insulation breakdown increases
Solution Approach 1:
The semi-conductive layer serves as an intermediary that manages electric field distribution between high-voltage conductors and the outer insulation environment. By controlling field concentration at critical interfaces, it enables the system to operate at elevated voltage and current levels without compromising insulation integrity, thus allowing increased power output while maintaining reliability.
Solution Approach 2:
The invention replaces reliance on mechanical insulation thickness with an electrostatic field management system. The conductive shield layer, when grounded, creates a controlled electrostatic environment that prevents partial discharges through field redistribution rather than physical barrier alone. This substitution enables higher power operation while maintaining insulation integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances the power density and operational efficiency of electric machines by preventing partial discharges at high altitudes and voltages, allowing for more compact designs while maintaining electrical integrity.
Implementation Method 1
a conductive shield layer overlying the insulation layer and having a terminal end conductively connected with the conductive shield layer
Implementation Method 2
a conductive shield layer overlying the insulation layer... preventing partial discharges
Implementation Method 3
an insulation layer overlying the conductive core
Data Source
AI summary
An electric winding assembly comprising a conductor core which includes at least a first end and a distal second end, an insulation layer overlying the conductor core, and a conductive shield layer overlying the insulation layer. The conductive shield layer further having a terminal end conductively connected with the conductive shield layer.