Design of universal insulation systems for low voltage and high voltage rotating electrical apparatus

The fabrication and repair of rotating electrical apparatus, specifically, electric motors and generators, has historically required the design and specification of electrical insulation systems optimized based on operating voltage. This apparatus specific design approach, while effective, necessitates a variety of electrical insulation system topologies and material choices. It is proposed that a universal insulation design approach with respect to material selection could eliminate the need for different materials, and duplication of processes in the fabrication and repair of rotating electrical apparatus. This winnowing of material selections has the potential to streamline the fabrication and repair process in facilities that operate on apparatus designed across the full range of nominal apparatus voltages, from low voltage to high voltage machines. Background on electrical insulation systems, design, fabrication, and performance is discussed. A series of candidate electrical insulation systems are proposed and evaluated for use in a universal insulation design approach. Candidate electrical insulation systems are evaluated experimentally on a host of factors including, chemistry and physical characteristics, electrical and thermal performance, along with regulatory and application challenges.

The fabrication and repair of rotating electrical apparatus, specifically, electric motors and generators, has historically required the design and specification of electrical insulation systems optimized based on operating voltage. This apparatus specific design approach, while effective, necessitates a variety of electrical insulation system topologies and material choices. It is proposed that a universal insulation design approach with respect to material selection could eliminate the need for different materials, and duplication of processes in the fabrication and repair of rotating electrical apparatus. This winnowing of material selections has the potential to streamline the fabrication and repair process in facilities that operate on apparatus designed across the full range of nominal apparatus voltages, from low voltage to high voltage machines. Background on electrical insulation systems, design, fabrication, and performance is discussed. A series of candidate electrical insulation systems are proposed and evaluated for use in a universal insulation design approach. Candidate electrical insulation systems are evaluated experimentally on a host of factors including, chemistry and physical characteristics, electrical and thermal performance, along with regulatory and application challenges. A candidate insulation system consisting of a non-Newtonian pseudo-plastic resin was identified in this research as successfully fulfilling the requirements of a universal insulation system.