General Electric Company

Christopher Michael Calebrese

Qin Chen

Jeffrey S Sullivan

Anil Raj Duggal

Benjamin Hale Winkler

Kevin Warner Flanagan

Lili Zhang

Karim Younsi

Konrad Roman Weeber

John Russell Yagielski

Wei Zhang

Robert Colin McTigue

Massimiliano Vezzoli

Han Xiong

Alexander Rene Anderton

Stephen Francis Francese

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.

Online and offline partial discharge detection for electrical drive systems

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.

System of a conductor disposed within an insulator

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.

Electrical propulsion system with corona suppression on a vehicle

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.

Electrical insulation systems and insulated components for electrical machine

Manufacturing method for a conductor disposed within an insulator

An electrical machine includes a stator assembly having an annular core and a conductive winding. The annular core includes a central bore. The conductive winding includes one or more stator winding bars disposed circumferentially around the central bore. The one or more stator winding bars include a core conductor and an insulation layer surrounding the core conductor. An end segment of the one or more stator winding bars at a connection interface includes a stress control structure surrounding the insulation layer. The stress control structure includes a printed scaffold and a dielectric backfill material. The dielectric backfill material fills pores of the printed scaffold. The porous scaffold is composed of a stress control material that is different from the dielectric backfill material.

Stator assembly with stress control structures

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.

Resistively graded insulation for stators

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Cohoes, NY, United States of America

Christopher Michael Calebrese