Comprehensive Modeling of SiC Inverter Driven Form Wound Motor Coil for Insights on Coil Insulation Stress

This paper comprehensively presents an approach for modeling form wound coils of a motor driven by an inverter, with focus on the electric stresses on the coil insulation. A 10 kV SiC testbed for medium voltage form wound coils was developed to support and validate the modeling techniques discussed. A finite element analysis (FEA) model of the motor coil is presented using COMSOL 6.1. The FEA model was used to determine parameters for an electrical model based on the multi-conductor transmission line theory. The linking of these models allows for a rapid analysis of the electrical stresses the insulation can be exposed to. An experimental method for model validation using the empirical transfer function estimation (ETFE) approach to find the impedance response of the testbed for comparison to the proposed electrical model is presented and employed. The paper also uses the model to analyze the impact of insulation delamination and voids and to demonstrate the implementation of a metric called insulation state of health monitoring for both healthy and damaged coils.